k9k Engine tech note 6006A Renault dci 1.5 diesel Kxx Repair manual

Technical Note6006A KXX, and K9K K9K engine Engine workshop repair manual

Edition 2

77 11 328 422

MARCH 2004

"The repair methods given by the manufacturer in this document are based on the technical specifications current when it was prepared. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed."

Edition Anglaise

All copyrights reserved by Renault. The reproduction or translation in part of whole of the present document, as well as the use of the spare parts reference numbering system, are prohibited without the prior written consent of Renault.

© Renault s.a.s. 2006

K9K engine

K9K engine ContentsPage

Contents Page

10A

ENGINE AND LOWER ENGINE ASSEMBLY Engine: Specifications Engine: Precautions for repair

10A-1 10A-4

10A

ENGINE AND LOWER ENGINE ASSEMBLY Piston base cooling jet: Removal

10A-207

Lower engine: Cleaning

10A-209

Lower engine: Check

10A-211

Engine: Parts and consumables for the repair work

10A-14

Piston base cooling jet: Refitting

10A-224

Upper engine: Tightening torque

10A-15

Running gear Refitting

10A-227

Cylinder block: Refitting

10A-239

Timing - cylinder head: Refitting

10A-280

Accessories belt: Refitting

10A-326

Engine: Refitting

10A-329

Timing belt: Removal

10A-336

Timing belts: Refitting

10A-351

Lower engine: Tightening torque

10A-20

Diesel injection: Tightening torque

10A-23

Accessories belt: Tightening torque

10A-26

Upper engine: Specifications

10A-28

Engine peripherals: Specifications

10A-36

Standard replacement

10A-46

Special tooling

10A-47

Equipment

10A-65

Engine: Dismantling

10A-84

Accessories belt: Removal

10A-89

Timing - cylinder head: Removal

10A-90

Cylinder head: Dismantling

10A-113

Upper engine: Cleaning

10A-129

Upper engine: Checking

10A-135

Cylinder head: Refitting

10A-144

Cylinder block: Dismantling

10A-192

Running gear:Removal

10A-204

ENGINE AND LOWER ENGINE ASSEMBLY Engine: Specifications I - ENGINE IDENTIFICATION

10A

Details of markings

19858

The markings consist of: - (1) : the engine type 107307

- (2) : the engine approval letter - (3) : the engine suffix - (4) : the factory where the engine was fitted - (5) : the engine production number

113741

The engine can be identified by markings (6) located on the cylinder block.

10A-1

ENGINE AND LOWER ENGINE ASSEMBLY Engine: Specifications

10A

II - ENGINE SPECIFICATION TABLES

Vehicle

AfterSales Type:

Engine type

Engine suffix

Cubic capacity (cc)

Bore (mm)

Stroke (mm)

Compression ratio

700

XB07 XB1W XB24

18.25:1

XB08 Renault CLIO II

702

XB07 XB24

704 K9K

1461

76

704

80.5

706

17.9:1

XB09

710

18.25:1

XB2G

712

17.9:1

XC07

700

XC08

702

XB23 XB2E

XC1S

18.25:1

XC07 Renault KANGOO

Renault MEGANE II

Renault CLIO III

704

XC08 XC1R

K9K

704

1461

76

80.5

17.6: 1

XC09

710

XC1E

714

XC1F

716

XC1G

718

XM0F

722

18.25:1

XM0T

722

17.6:1

XM1F

18.25:1

17.9:1

724 K9K

17.9:1 1461

76

80.5

XM02

728, 729

17.9:1

XM13

728

17.6: 1

XM1E

732

15.3:1

XR0H

764

15.3:1

XR0F

K9K

766

1461

76

80.5 17.9:1

XR0G

768

10A-2

ENGINE AND LOWER ENGINE ASSEMBLY Engine: Specifications Vehicle

AfterSales Type:

Engine type

Engine suffix

XP0D

750

XP08

752

Cubic capacity (cc)

Bore (mm)

10A Stroke (mm)

Compression ratio

17.6: 1

XP0E Renault MODUS

Renault DACIA

XP0F

K9K

760

1461

76

80.5

17.9:1

XP0G

762 ,768

XP0H

764

15.3:1

XP0F

766

17.9:1

XS0J

790 K9K

XS0K

1461

76

80.5

17.9:1

792

Nissan ALMERA

-

K9K

260

1461

76

80.5

18.25:1

Nissan MICRA

-

K9K

270, 272, 274, 276

1461

76

80.5

18.25:1

10A-3

ENGINE AND LOWER ENGINE ASSEMBLY Engine: Precautions for repair

10A

c - Reliability - updating Equipment required

Since component specifications are subject to change during their commercial life, it is essential to check whether there are any Technical Note updates when seeking information.

offset thread repair kit

I - SAFETY d - Safety General information All information contained in these manuals is intended exclusively for automotive industry professionals. The documentation is intended to cover all vehicles in the RENAULT range throughout the world, but may not cover equipment designed for use in specific countries.

Certain devices and parts must be handled with particular attention to safety and cleanliness and, above all, with due care. The safety symbol used in this manual indicates that special attention must be paid to the procedure or the tightening torque values.

The methods and fault finding procedures recommended and described in this manual have been designed by automotive industry repair professionals.

WARNING Do not use flammable products to clean parts. Working safely:

a - General recommendations

- use appropriate tools which are in good condition (using « multipurpose » tools, such as adjustable pliers, should be avoided wherever possible),

Observe basic principles of vehicle repair. The quality of repair depends first and foremost on the care exercised by the person in carrying it out. To ensure good repair: - use recommended professional products and original Renault parts,

- adopt a correct posture and technique when performing heavy work or lifting loads, - check that the working area is clean and tidy during the operation,

- observe the tightening torques,

- use personal protection (gloves, safety goggles, work shoes, masks, skin barrier creams, etc.),

- replace the recommended roll pins, nuts or bolts, after each removal,

- always follow the safety instructions associated with the operation to be performed,

- clean and degrease the sections to be bonded, to ensure they bond correctly.

- do not smoke when working on vehicles,

The design quality of our vehicles demands that nothing is left to chance in making a good repair, and it is essential to refit parts or components exactly as they were originally (for instance: heat shields, wiring routing, pipe routing).

- do not ingest any chemicals (brake fluid, coolant, etc.).

Use professional products and apply them with care, for example do not apply too much sealant to the joint face.

- do not burn waste products (tyres, etc.).

- do not use toxic products in unventilated rooms,

Respecting the environment: - sort waste according to its particular qualities,

e - Conclusion b - Special tooling - ease of use The repair procedures have been designed using special tools; they must therefore be carried out using these tools to ensure a high degree of working safety and quality of repair. The equipment we have approved has undergone careful research and testing, and must be used and maintained with care.

The procedures contained in this document merit your attention. Please read them carefully in order to reduce the risk of injury, and avoid using incorrect procedures that could damage the vehicle or make it dangerous to use. Following the recommended procedures will help you to provide a quality of service which will ensure the vehicles achieve the highest levels of performance and reliability.

10A-4

ENGINE AND LOWER ENGINE ASSEMBLY Engine: Precautions for repair Maintenance and repair operations must be carried out under the proper conditions to ensure that our vehicles run safely and reliably.

10A

The use of rags or ordinary paper towels is prohibited: these produce lint and lose fibres, which then contaminate the fuel circuit. Each cloth must only be used once.

II - CLEANLINESS Risks relating to contamination

b - Blanking plugs

The high-pressure direct injection system is highly sensitive to contamination. The risks caused by contamination are:

The blanking plugs are used to cap the fuel circuit once it is opened and to therefore prevent contaminants from entering.

- damage to or destruction of the high-pressure injection system,

A set of blanking plugs should be used once only and used plugs must be discarded after use: once used, the plugs are soiled and cleaning them is not sufficient to make them reusable.

- a component seizing, - a component not being properly sealed. All After-Sales operations must be performed under very clean conditions. Having carried out an operation in good conditions means that no impurities (particles a few microns in size) have penetrated the system during dismantling. The cleanliness principle must be applied from the filter to the injectors.

Unused plugs must also be discarded and not used again for any other operation on an injection system. Blanking plug kit part number: - K9K ( DELPHI injection): 77 01 206 804 - K9K ( SIEMENS injection): 77 01 476 857

What are the sources of contamination? c - Protective bags

- metal or plastic chips,

Use hermetically resealable plastic bags, using adhesive tape, for example, to store components which will be refitted and reused. Stored parts will therefore be less subject to the risk of contamination.

- paint, - fibres: • cardboard,

These bags must be used once only: once they have been used, they are to be discarded.

• brushes, • paper, • clothing,

d - Cleaning products

• cloth,

Two cleaning products can be used:

- foreign bodies such as hair, - an aerosol spray brake cleaner (part number 77 11 226 128 ).

- ambient atmosphere, - etc.

- an injector cleaner (part number 77 11 224 188 ), To use the injector cleaner, be sure to have a clean brush in good condition (the brush must not lose any bristles) as well as a clean container which has no impurities in it.

WARNING Cleaning the engine using a high-pressure washer is prohibited because of the risk of damaging connections. In addition, moisture may collect in the connectors and create electrical connection faults.

Note: a - Cleaning cloths Use lint free cleaning cloths (part number 77 11 211 707 ).

10A-5

Use a new injector cleaner each time work is carried out (a used cleaning agent will contain impurities).

ENGINE AND LOWER ENGINE ASSEMBLY Engine: Precautions for repair III - GENERAL RECOMMENDATIONS

10A

After opening the fuel circuit, the use of brushes, cleaning agents, air blow guns, rifle-type brushes or standard cloths is strictly prohibited: These items are likely to allow impurities to enter the system.

1 - Advice to be followed before any operation 1) Carry out the work in a clean working area and take care to protect removed components from dust using plastic bags which are hermetically resealable, for example.

When replacing a component with a new one or when refitting it after storing it in a plastic bag, do not unpack it until it is time to fit it on the vehicle.

2) Always order the following from the Parts Department before carrying out work:

3 - Cleaning

- a new blanking plug kit ; these are specific to the engine

There are currently two procedures for cleaning the fuel circuit before opening it in order to carry out work in the workshop.

- a sufficient number of lint free cleaning cloths . - one of the two cleaning products for fuel pipe unions, - the parts always to be replaced after each removal operation mentioned in the operational procedures specific to the vehicle. 3) Wear safety goggles fitted with side shields to prevent the cleaning product from splashing the eyes. 4) Wear latex safety gloves to avoid prolonged contact with the skin.

These procedures enable the fuel circuit to be cleaned to prevent contamination from entering: they both have the same end result and neither is preferred over the other. a - Using the injector cleaning agent Clear the access to the unions that need opening, following the work procedures specific to the vehicle (see the relevant Workshop Repair Manual). Protect sections which are sensitive to fuel leaks. Pour the injector cleaning agent into a container which is free from impurities.

Note: If wearing leather protective gloves, cover these with latex gloves.

IMPORTANT Wear latex safety gloves when using the cleaning agent.

5) Before any operation on the injection system, using plastic bags or clean cloths, protect: - the accessories and timing belts, - the electrical accessories (starter, alternator, powerassisted steering pump, sensors and electrical connectors),

Dip a clean brush, which is not shedding bristles, into the container of injector cleaning agent.

IMPORTANT

- the flywheel face.

Wear safety goggles fitted with side shields during this operation.

2 - Instructions to be followed during the operation Wash your hands before and while carrying out the work. Change the latex safety gloves if they become soiled or damaged. All components removed from the injection system must be stored in a hermetically sealed plastic bag once they have been capped. Reseal the bag hermetically using adhesive tape, for example, even if the bag must be opened shortly afterwards: ambient air can be a source of pollution.

Clean the unions carefully using the brush and the injector cleaning agent. Blast the components that have been cleaned with compressed air (tools, workbench, and also parts, unions and around the injection system). Make sure there are no brush bristles remaining and that the area is clean. Wipe the sections that were cleaned with fresh cleaning cloths. Open the circuit at the unions and immediately fit the relevant blanking plugs.

10A-6

ENGINE AND LOWER ENGINE ASSEMBLY Engine: Precautions for repair

WARNING Do not blast with compressed air once the fuel circuit is open, otherwise impurities may enter the system. Use cleaning cloths only, if necessar y. b - Using the brake cleaning agent Clear the access to the unions that need opening, following the work procedures specific to the vehicle (see the relevant Workshop Repair Manual). Protect sections which are sensitive to fuel leaks.

IMPORTANT Wear latex safety gloves when using the cleaning agent.

IMPORTANT Wear safety goggles fitted with side shields during this operation. Spray the brake cleaning agent onto the unions to be opened. Clean the unions carefully using fresh cleaning cloths. Blast the components that have been cleaned with compressed air (tools, workbench, and also parts, unions and around the injection system). Make sure there are no brush bristles remaining and that the area is clean. Open the circuit at the unions and immediately fit the relevant blanking plugs.

WARNING Do not blast with compressed air once the fuel circuit is open, otherwise impurities may enter the system. Use cleaning cloths only, if necessar y.

10A-7

10A

ENGINE AND LOWER ENGINE ASSEMBLY Engine: Precautions for repair 4 - Instructions for fitting the plugs K9K, and 732 or 764

10A-8

10A

ENGINE AND LOWER ENGINE ASSEMBLY Engine: Precautions for repair

10A

Part no. 77 01 476 857

113430

10A-9

ENGINE AND LOWER ENGINE ASSEMBLY Engine: Precautions for repair

10A-10

10A

ENGINE AND LOWER ENGINE ASSEMBLY Engine: Precautions for repair

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 714 or 716 or 718 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 766 or 768 or 790

10A-11

10A

ENGINE AND LOWER ENGINE ASSEMBLY Engine: Precautions for repair

10A

Part no. 77 01 206 804

20977

10A-12

ENGINE AND LOWER ENGINE ASSEMBLY Engine: Precautions for repair

5 - Engine cleaning Protect the various accessories to prevent water and cleaning products splashing on them. Do not allow water to enter the inlet pipes. 6 - Cleaning the engine parts

WARNING When cleaning parts, it is essential to not knock the parts against each other, or their mating faces may be damaged and therefore their adjustments may be altered, which could damage the engine. 7 - Fitting relieved threads The tapped holes of all parts including the engine (except the rocker cover) may be repaired using the offset thread repair kit .

10A-13

10A

ENGINE AND LOWER ENGINE ASSEMBLY Engine: Parts and consumables for the repair work I - PARTS ALWAYS TO BE REPLACED AFTER REPAIRING THE ENGINE - All seals - The oil filter

10A

- The camshaft pulley nut - The tensioning rollers and pulleys for the accessories and timing belts

- The copper washers on the injector holders,

- The bolts for the accessories belt mechanical tensioning roller

- The high pressure injection pipes,

- The accessories and timing belts

- The pipe plugs,

- The crankshaft accessories pulley bolt

- The valve guides

- The cooling circuit hoses if they are damaged

- The valve stem seals

- The thermostat

- The cooling jets at the bottom of the piston

- The turbocharger plastic pipes.

- The engine flywheel bolts - The crankshaft bearing cap bolts

II - CONSUMABLES

- The con rod cap bolts Type

Quantity

Component concerned

Part no.

DÉCAPJOINT

Coat

The joint faces

77 01 405 952

SILICONE ADHESIVE SEAL

Bead

Crankshaft bearing cap no. 1

77 11 227 484

LOCTITE 518

Bead

Camshaft bearing caps no. 1 and no. 6

77 01 421 162

"VARYBOND 12-71" HIGH STRENGTH THREADLOCK

1 - 2 drops

Coolant pump bolts

77 11 230 112

DEGREASER

Coat

The joint faces

77 11 224 559

CLEANING CLOTHS

-

Injection circuit

77 11 211 707

SET OF BLANKING PLUGS

-

Injection system DELPHI

77 01 206 804

SET OF BLANKING PLUGS

-

Injection system SIEMENS

77 01 476 857

INJECTOR CLEANING PRODUCT

Coat

Injection system

77 11 224 188

BRAKE CLEANER

Coat

Injection system

77 11 226 128

GREY SCUFF PAD

-

The joint faces

77 01 405 943

Cylinder block-sump connection

10A-14

ENGINE AND LOWER ENGINE ASSEMBLY Upper engine: Tightening torque UPPER ENGINE

10A-15

10A

ENGINE AND LOWER ENGINE ASSEMBLY Upper engine: Tightening torque

10A

113915

10A-16

ENGINE AND LOWER ENGINE ASSEMBLY Upper engine: Tightening torque

10A

Tightening torques in Nm and/or in degrees (1)

cylinder marking sensor bolt

8 ± 0.8

(2)

Rocker cover bolts

12 ± 1.2

(3)

Lifting eye bolts (timing end)

Bolt H M8x125-16 21 ± 2.1 Bolt H M6x100-23 10 ± 1

(4)

Cylinder head bolts

± 10˚ 25 ± 2.5 + 255˚±

(5)

Camshaft bearing cap bolts

11 ± 1.1

(6)

Vacuum pump bolt

21 ± 2.1

(7)

Exhaust manifold nut

26 ± 2.6

(8)

Exhaust manifold stud

8 ± 0.8

(9)

EGR cooler cover bolt

12 ± 1.2

(10)

Cylinder head coolant pipe housing outlet bolt

11 ± 1.1

(11)

Engine lifting eye bolts (flywheel end)

13 ± 1.3

(12)

Inner timing cover bolt

9 ± 0.9

(13)

Heater plug

15 ± 1.5

(14)

Timing tension wheel bolt

27 ± 2.7

(15)

Camshaft pulley stud

10 ± 1 at 14 ± 1.4

(16)

Camshaft pulley nut

± 6˚ 30 ± 3 + 86˚±

(17)

Camshaft pulley ring gear bolt

14 ± 1.4

(18)

Cylinder marking sensor bolt

8 ± 0.8

(19)

Cylinder head suspended mounting bolt

25 ± 2.5

10A-17

ENGINE AND LOWER ENGINE ASSEMBLY Upper engine: Tightening torque

10A

113916

Couple de serrage en N.m et / ou degrés (20)

Downstream catalytic converter stay nut and bolt (gearbox side)

21 ± 2.1

(21)

Upstream catalytic converter stay bolt (engine side)

44 ± 4.4

(22)

Upstream stay bolt on the catalytic converter

26 ± 2.6

(23)

Catalytic converter-turbocharger nut

26 ± 2.6

(24)

Downstream stay bolt on the catalytic converter

21 ± 2.1

(25)

Turbocharger stud

9 ± 0.9

(26)

Turbocharger oil supply pipe bolt on the turbocharger.

23 ± 2.3

(27)

Turbocharger nut on the manifold

26 ± 2.6

(28)

Turbocharger oil supply pipe bolt on the cylinder head

Collar nut to 35 ± 3.5 (without high strength threadlock) Collarless nuts to 23 ± 2.3 (with high strength threadlock)

(29)

9 ± 0.9

Turbocharger stud

10A-18

ENGINE AND LOWER ENGINE ASSEMBLY Upper engine: Tightening torque

10A

Couple de serrage en N.m et / ou degrés (30)

Turbocharger oil return pipe bolt

12 ± 1.2

(31)

Timing end cooler support bolt

25 ± 2.5

(32)

Exhaust gas cooler bolt

12 ± 1.2

(33)

EGR solenoid valve bolt

10 ± 1

(34)

Flywheel end cooler support bolt

25 ± 2.5

(35)

Exhaust gas inlet pipe bolts

35 ± 3.5

(36)

Timing end cooler support bolt

12 ± 1.2

(37)

Exhaust gas recirculation solenoid valve bolt

12 ± 1.2

(38)

Exhaust gas recirculation solenoid valve stud

4 ± 0.4

(39)

Exhaust gas recirculation solenoid valve nut

12 ± 1.2

(40)

Solenoid valve support bolts

21 ± 2.1

10A-19

ENGINE AND LOWER ENGINE ASSEMBLY Lower engine: Tightening torque LOWER ENGINE:

10A-20

10A

ENGINE AND LOWER ENGINE ASSEMBLY Lower engine: Tightening torque

10A

113917

10A-21

ENGINE AND LOWER ENGINE ASSEMBLY Lower engine: Tightening torque

10A

Couple de serrage en N.m et / ou degrés (1)

coolant pump bolts

11 ± 1.1

(2)

Crankshaft cover bolts

11 ± 1.1

(3)

Dipstick guide tube bolts

10 ± 1

(4)

Coolant pump inlet pipe bolts

22 ± 2.2

(5)

The water-coolant heat exchanger union

45 ± 4.5

(6)

Oil filter bracket bolt

45 ± 4.5

(7)

Coolant pump inlet pipe bolts

22 ± 2.2

(8)

Crankshaft accessories pulley bolt

Bolt M12: 60 ± 6 +100˚ ± 10˚ Bolt M14: 120 ± 12 + 95˚ ± 15˚

(9)

Oil pump bolts

25 ± 2.5

(10)

Oil sump bolts

14 ± 1.4

(11)

Oil level sensor

25 ± 2.5

(12)

Drain plug

20 ± 4

(13)

Clutch pressure plate bolts

Bolt H M7x100-16: 20 ± 2 Bolt CBLX M6x100-18: 14 ± 1.4

Flywheel bolts

55 ± 5.5

Dual-mass flywheel bolts

± 6˚ 20 ± 2 + 36˚±

(15)

Con rod cap bolt

± 6˚ 20 ± 2 + 45˚±

(16)

Oil pressure switch

30 ± 3 to 35 ± 3.5

(17)

TDC pin plug

20 ± 2

(18)

Crankshaft bearing cap bolts

25 ± 2.5 + 47˚ ± 6˚

(19)

Accelerometer

20 ± 2

(20)

Oil filter

14 ± 2

(14)

10A-22

ENGINE AND LOWER ENGINE ASSEMBLY Diesel injection: Tightening torque INJECTION SYSTEM

10A-23

10A

ENGINE AND LOWER ENGINE ASSEMBLY Diesel injection: Tightening torque

10A

113914

10A-24

ENGINE AND LOWER ENGINE ASSEMBLY Diesel injection: Tightening torque

10A

Tightening torque in Nm and/or degrees (1)

High pressure guard mounting nut and bolt

10 ± 1

(2)

High pressure pump bolt

21 ± 2.1

(3)

Rail-injector high pressure pipe nuts

See insert

(4)

Injector bracket bolt

30 ± 3

(5)

High pressure rail stud

8 ± 0.8

(6)

High pressure rail nut

28 ± 2.8

(7)

High pressure pump-rail high pressure pipe

See insert

(8)

Lower high pressure guard nut and bolt

21 ± 2.1

(9)

High pressure guard cover bolt

10 ± 1

(10)

High pressure pump sprocket nut

55 ± 5.5

(11)

Rail-injector high pressure pipe nuts

24 ± 2.4

(12)

Injector bracket bolt

28 ± 2.8

(13)

High pressure rail nut

± 2.8 28±

(14)

High pressure pump-rail high pressure pipe

24 ± 2.4

(15)

Lower high pressure guard and hose bracket nuts

21 ± 2.1

(16)

Lower high pressure guard bolts

10 ± 1

(17)

High pressure guard cover bolt

10 ± 1

(18)

High pressure guard bracket bolts

10 ± 1

(19)

High pressure pump bolts

21 ± 2.1

WARNING Tighten to a torque of 38 ± 3.8 Nm the pump-rail and rail-injector high pressure pipes, part numbers: - 77 01 207 025 , - 77 01 207 026 , - 77 01 207 027 , - 77 01 207 028 . For high pressure pipes with different part numbers, tighten to a torque of 24 ± 2.4 Nm .

10A-25

ENGINE AND LOWER ENGINE ASSEMBLY Accessories belt: Tightening torque

10A

I - ACCESSORIES PANEL ON VEHICLES WITHOUT AIR CONDITIONING

106962

Tightening torque in Nm and/or degrees (1)

Pulley bolt

21 ± 2.1

(2)

Power-assisted steering pump bolt

21 ± 2.1

(3)

Power-assisted steering pump stay bolt

21 ± 2.1

(4)

Multifunction support bolts

44 ± 4.4

(5)

Tensioning roller bolts

35 ± 3.5

(6)

Alternator bolt

21 ± 2.1

10A-26

ENGINE AND LOWER ENGINE ASSEMBLY Accessories belt: Tightening torque

10A

II - ACCESSORIES PANEL ON VEHICLES WITH AIR CONDITIONING

106963

Tightening torque in Nm and/or degrees (1)

Air conditioning compressor bolt

21 ± 2.1

(2)

Alternator bolts

21 ± 2.1

(3)

Auto tensioner bolts

40 ± 4

(4)

Multifunction support bolts

44 ± 4.4

(5)

Multifunction support lower bolt

21 ± 2.1

10A-27

ENGINE AND LOWER ENGINE ASSEMBLY Upper engine: Specifications

10A

I - POSITION OF THE CYLINDERS Cylinder no. 1 is at the flywheel end.

Engine type

Thickness of the cylinder head gasket in mm

II - INJECTION SEQUENCE The injection sequence is 1-3-4-2 . K9K 260-270-272 III - HEATER PLUG

Type of plug

K9K 700-702-704-710 until 19/05/2004 .

up

Resistance

K9K 722 up until 16/07/ 2004 .

0.6 Ω

K9K 700-702-704-710 from 19/05/2004 .

0.68 ± 0.03

BERU CHAMPION

K9K 722 from 16/07/2004 . IV - CYLINDER HEAD GASKET

K9K 274-276-706-712-714716-718-724-728-729-732750-752-760-762-764-766-768-790-792

0.71 ± 0.03

V - CYLINDER HEAD

20059

The thickness of the cylinder head gasket is measured at (1) .

21702

1 - Cylinder head height The cylinder head height (2) is 127mm . 2 - Cylinder head gasket face bow The maximum cylinder head gasket face bow is 0.05mm .

10A-28

ENGINE AND LOWER ENGINE ASSEMBLY Upper engine: Specifications 3 - Cylinder block gasket face bow The maximum cylinder block gasket face bow is 0.03mm .

10A

3 - Diameter of the tappet housing in the cylinder head The diameter of the tappet housing in the cylinder head is 35.02 ± 0.02mm

4 - Cylinder head testing Test the cylinder head for possible cracks using the cylinder head test kit .

4 - Clearance between the tappet and its housing The clearance between the tappet and its housing is between 0.015 and 0.075mm .

5 - Cylinder head regrinding

VII - ADJUSTING VALVE CLEARANCES

WARNING No regrinding is permitted.

Valves

Cold valve clearance in mm

Inlet

0.20 + 0.05 / - 0.075

Exhaust

0.40 + 0.05 / - 0.075

VI - TAPPET 1 - Tappet type The tappet is the monobloc type. VIII - VALVES

2 - Outer diameter of tappet

103157

102778

The outer diameter of the tappet is 34.975 ± 0.01mm . Inlet valve

Exhaust valve

Diameter (D) of the valve stem is measured at point (X1)

(D) = 5.977 ± 0.008mm at (X1) = 41mm .

(D) = 5.963 ± 0.008mm at (X1) = 31mm .

Diameter (D) of the valve face

33.5 ± 0.12mm

29 ± 0.12mm

Thickness (T) of the valve head

1mm

1mm

Length (L) of the valve

100.95 ± 0.21mm

100.75 ± 0.21mm

Valve seat angle (A)

90˚

90˚

Valve lift

8mm

8.6mm

10A-29

ENGINE AND LOWER ENGINE ASSEMBLY Upper engine: Specifications

10A

IX - VALVE SEATS

87428

Inlet valve seat

Exhaust valve seat

Internal diameter of the valve seat housing (D) in the cylinder head

34.459 ± 0.015mm

29.97 ± 0.015mm

Outer diameter (D) of the valve seat

34.542 ± 0.008mm

30.042 + 0.006 / - 0.007mm

Valve seat housing depth (H) in the cylinder head

6mm

7mm

Valve seat height (H)

4.65 ± 0.04mm

5.67 ± 0.04mm

Width of mating faces X

1.8mm

1.8mm

Angle α of the valve seat

89˚30’

89˚30’

X - VALVE GUIDES

21702

10A-30

ENGINE AND LOWER ENGINE ASSEMBLY Upper engine: Specifications

Inlet guide

10A

Exhaust guide 40.5 ± 0.15mm

Length of the valve guide External diameter of guide:

11 + 0.062 / + 0.044mm

Diameter of the guide housing in the cylinder head:

11mm

Internal diameter of the valve guide Non machined Machined *

5 + 0.12 / 0mm 6.009 ± 0.009mm

Valve guide angle of inclination (A)

90˚

Valve guide position (X)

14mm

14.2mm

Clearance between the valve guide and the valve

0.02 to 0.05mm

0.03 to 0.063mm

* This dimension is measured with the guide fitted in the cylinder head. XI - VALVE STEM SEALS The inlet and exhaust guides have valve stem seals. These must be replaced each time the valves are removed.

18077

98503

The removal of the valve stem seals is carried out using ( Mot. 1335 ).

10A-31

ENGINE AND LOWER ENGINE ASSEMBLY Upper engine: Specifications

10A

19675

The valve stem seals are refitted using either: - a suitable tool, or - tool ( Mot. 1511-01 ). 102776

XII - VALVE SPRINGS Free length

43.31mm

Length under a load of: - 230 ± 12 N - 500 ± 23 N

33.80mm 24.80mm

Length, coils touching

23.40mm

Diameter of the wire

3.45mm

Internal diameter: - at the base of the spring

18.80 ± 0.2mm

- at the top of the spring

14.10 ± 0.2mm

External diameter:

16051-1

- at the base of the spring

25.70 ± 0.2mm

- at the top of the spring

21 ± 0.2mm

The inlet and exhaust valve springs are identical. The valve springs are the conical type and part (3) of the spring must face upwards.

WARNING CE MOTEUR NE POSSEDE PAS DE RONDELLES INFERIEURES DE RESSORT DE SOUPAPE.

10A-32

ENGINE AND LOWER ENGINE ASSEMBLY Upper engine: Specifications

10A

3 - Camshaft radial play The radial play must be between 0.04 and 0.081mm . 4 - Camshaft eccentricity.

102774

Spring perpendicularity 1.2mm XIII - CAMSHAFT 1 - Identifying the camshaft

103148

The camshaft eccentricity is 0.05mm . 5 - Number of camshaft bearings The camshaft has 6 bearings.

113568

With certain engines the camshaft has a target (4) for aligning the cylinders.

Engine type K9K 260-270-272-274276-700-702-704-706710-712-714-716-718722-724-728-729-750752-760-762-766-768790-792 K9K 732 - 764

Camshaft type

WITHOUT the target (4) WITH the target (4)

2 - Camshaft longitudinal play The longitudinal play must be between 0.08 and 0.178mm .

10A-33

ENGINE AND LOWER ENGINE ASSEMBLY Upper engine: Specifications

10A

6 - Camshaft bearing diameters

Number of bearings

Diameter of camshaft bearings on the camshaft

Diameter of camshaft bearings on the cylinder head

24.9895 ± 0.0105mm

25.05 ± 0.01mm

27.9895 ± 0.0105mm

28.05 ± 0.01mm

No. 1 No. 2 No. 3 No. 4 No. 5 No. 6

8 - Valve timing Note: The no. 1 camshaft bearing is located at the flywheel end. 7 - Cam height

11953

- 1 TDC fixed marking on the cylinder block, - 2 TDC movable marking on the flywheel, - 3 BDC movable marking on the flywheel, 103149

- 4 Inlet Opening Retardation ROA *, - 5 Exhaust Closing Advance AFE **,

Inlet Cam height

44.015 0.03mm

Exhaust ±

44.595 0.03mm

- 6 Inlet Closing Retardation RFA , ±

- 7 Exhaust Opening Advance AOE , - 8 Crankshaft direction of rotation (flywheel end).

10A-34

ENGINE AND LOWER ENGINE ASSEMBLY Upper engine: Specifications

10A

Theoretical settings for a lift of 0.7mm (no clearance) Note: *If the

TDC. **If the

Inlet

Exhaust

Inlet Opening Retardation ROA

-9˚

-

Inlet Closing Retardation RFA

20˚

-

Exhaust Opening Advance AOE

-

27˚

Exhaust Closing Advance AFE

-

-7˚

ROA is negative, the valve will open after AFE is negative, the valve will close before

TDC.

XIV - TURBOCHARGER Turbocharging pressure regulation valve

Pressure regulation valve value in bar

Valve rod movement value in mm

Engine type

Pressure

Vacuum

K9K 272-700-704-710-752790

1.3

-

1.95 ± 0.6

K9K 260-270-702-706-722750

1.4

-

4.3 ± 0.6

K9K 712-728-729-732-764

-

0.5

1.7

K9K 276-718-724-760-766

-

0.6

7 ± 0.5

K9K 274-714-716-762-768792

1.1

-

2.2 ± 0.5

10A-35

ENGINE AND LOWER ENGINE ASSEMBLY Engine peripherals: Specifications I - PISTONS

10A

3 - Piston markings

1 - Piston brand These engines are fitted with FEDERAL MOGUL pistons. 2 - Piston combustion chamber volume

21703

(1) Direction of fitting the piston Λ facing the flywheel. (2) Gudgeon pin height class which corresponds to the height between the gudgeon pin and the piston crown. (3) Used by the supplier only. (4) Used by the supplier only. 102694

(5) Used by the supplier only. Engine type

Piston combustion chamber volume

K9K 260-270-272274-276-700-702-704706-710-712-714-716718-722-724-728-729750-752-760-762-766768-790-792

16.418 ± 0.25 cc

K9K 732-764

19.96 ± 0.25 cc

(6) Piston axis of symmetry. (7) Gudgeon pin hole axis. (8) Offset between gudgeon pin hole and piston axis of symmetry is 0.3mm .

10A-36

ENGINE AND LOWER ENGINE ASSEMBLY Engine peripherals: Specifications 4 - Gudgeon pin height classes

10A

Dimension (X1) represents the height of the gudgeon pin. Dimension (D) represents the gudgeon pin diameter.

102694

Diameter of gudgeon pin D = 25mm

Diameter of gudgeon pin D = 26mm

Engine type Piston gory

K9K 260-700-702704-710-722 up until 25/11/2002

K9K 260-700-702704-710-722 from 25/ 11/2002 K9K 270-272-274706-714-716-750-752762-768-790-792

cate-

Gudgeon pin height in mm

Piston gory

K*

41.646 41.687

to

-

-

L*

41.688 41.730

to

-

-

M*

41.731 41.772

to

-

-

N*

41.773 41.814

to

-

-

P

41.815 41.856

to

-

-

-

-

K*

41.646 41.687

to

-

-

L*

41.688 41.730

to

-

-

M*

41.731 41.772

to

-

-

N*

41.773 41.814

to

-

-

P

41.815 41.856

to

10A-37

cate-

Gudgeon pin height in mm

ENGINE AND LOWER ENGINE ASSEMBLY Engine peripherals: Specifications Diameter of gudgeon pin D = 25mm

10A

Diameter of gudgeon pin D = 26mm

Engine type Piston gory

K9K 276-712-718724-728-729-732-760764-766

cate-

Gudgeon pin height in mm

Piston gory

cate-

Gudgeon pin height in mm

-

-

J

41.605 41.646

to

-

-

K*

41.647 41.688

to

-

-

L*

41.689 41.730

to

-

-

M*

41.731 41.772

to

-

-

N

41.773 41.814

to

5 - Piston diameter Note: * = piston sold by the Parts Department. X2

WARNING - For engines K9K 260-270-274-700-702-704-706710-714-716-722-750-752-762-768-790-792 fitted with gudgeon pins of diameter D = 25 or 26mm , the Parts Department will only supply four categories of piston K, L, M, N . - If the engine is fitted with a category P piston, replace it with a category N piston. 10027

WARNING

The piston diameter must be measured with (X2) = 56mm

- For engines K9K 276-712-718-724-728-729-732760-764-766 , the Parts Department will only supply three categories of piston K, L, M . - If the engine is fitted with a category J piston, replace it with a category K piston. - If the engine is fitted with a category N piston, replace it with a category M piston.

Engine type

Piston diameter in mm

K9K 260-270-272274-700-702-704-706710-714-716-722-750752-762-768-790-792

75.949 ± 0.007

K9K 276-712-718724-728-729-732-760764-766

75.945 ± 0.007

6 - Gudgeon pin Fitting the free floating pin in the con rod and in the piston.

10A-38

ENGINE AND LOWER ENGINE ASSEMBLY Engine peripherals: Specifications The gudgeon pin is retained by circlips.

10A

7 - Piston protrusion

WARNING The dial gauge rod must not be in a valve clearance.

12962

Length (L)

Gudgeon pin dimensions in mm

Engine type

60 +0 / -0.3

All K9K

25 +0 / -0.005

K9K 260-700-7027 0 4 - 7 1 0 - 7 2 2 up until 25/11/2002

26 +0 / -0.005

K9K 260-700-702704-710-722 from 25/11/2002

20174

External diameter (D)

K9K 270-272-274276-706-712-714716-718-724-728729-732-750-752760-762-764-766768-790-792 13.75 +0.1 / 0.2

K9K 260-700-7027 0 4 - 7 1 0 - 7 2 2 up until 25/11/2002

13.5 +0.1 / -0.2

K9K 260-700-702704-710-722 from 25/11/2002

Internal diameter (d)

K9K 270-272-274276-706-712-714716-718-724-728729-732-750-752760-762-764-766768-790-792

Chamfer diameter (C)

20 ± 0.25

Chamfer length (l)

6

K9K 732-764

10A-39

Engine type

Piston protrusion in mm

K9K 260-700-702-704710-722 up until 25/11/ 2002

0.192 ± 0.093

K9K 260-700-702-704710-722 from 25/11/ 2002

0.154 ± 0.130

K9K 270-272-706-750752-790 K9K 274-276-712-714716-718-724-728-729732-760-762-764-766768-792

0.159 ± 0.129

ENGINE AND LOWER ENGINE ASSEMBLY Engine peripherals: Specifications II - PISTON RINGS

10A

III - CON RODS

T

1 - Type of con rod

1 2 3

12115

Piston rings are supplied ready adjusted. 16242

(T) = TOP The con rods are of the "SPLIT" type. 1 - Thickness of the piston rings

Piston rings

Thickness (in mm)

Compression ring (1)

2 -0.01 / -0.03

Sealing ring (2)

2 -0.01 / -0.03

Scraper ring (3)

2.5 -0.01 / -0.03

Note: The con rod small end bushes cannot be replaced. 2 - Guidelines for marking con rods

2 - Piston ring clearance in groove

Piston rings

Piston ring clearance in mm

Compression

0.2 to 0.35

Sealing

0.7 to 0.9

Scraper

0.25 to 0.5

103280

10A-40

ENGINE AND LOWER ENGINE ASSEMBLY Engine peripherals: Specifications

10A

IV - CRANKSHAFT WARNING

1 - Crankshaft markings

Do not use a punch or an etching tool to mark the con rod caps to match their bodies, to prevent incipient breakage of the con rod.

Marking one

Use an indelible marker pen. 3 - Weigh difference for the con rod-pistongudgeon pin assembly The maximum weight difference for the con rod-pistongudgeon pin assembly for the same engine must be 25 g. 4 - Con rod dimensions

Con rod dimensions in mm

Engine type

Distance between big end and little end centres

133.75

All K9K

Big end diameter

47.619 ± 0.009

All K9K

25.019 ± 0.006

K9K 260-700-7027 0 4 - 7 1 0 - 7 2 2 up until 25/11/2002

26.019 ± 0.006

K9K 260-700-702704-710-722 from 25/11/2002

Small end diameter (with bush)

14512-1

Marking two

K9K 270-272-274276-706-712-714716-718-724-728729-732-750-752760-762-764-766768-790-792

5 - Big end longitudinal play The longitudinal play must be between 0.205 and 0.467mm . 103689

6 - Big end radial play The radial play must be between 0.010 and 0.064mm .

10A-41

ENGINE AND LOWER ENGINE ASSEMBLY Engine peripherals: Specifications Marking "A" in detail

10A

4 - Crankshaft lateral play: The lateral play of the crankshaft must be between: - Without crankshaft lateral shim wear 0.045 and 0.252mm , - With crankshaft lateral shim wear 0.045 and 0.852mm . 5 - Journal radial play The radial play of the journals must be between 0.010 and 0.054mm . 6 - Number of journals 107878

(5) : line indicating the diameter category of the journals,

There are 5 journals. V - CYLINDER BLOCK

(6) : diameter category of journal no. 1, flywheel end, 1 - Diameter of the shafts

(7) : diameter category of journal no. 5, timing end, (8) : diameter category of crankpin no. 1, flywheel end,

This engine only has one category of shaft diameter 76.009 ± 0.015mm

(9) : diameter category of crankpin no. 4, timing end, (10) : line indicating the diameter category of the crankpins.

2 - Identifying the bearing journal diameters on the cylinder block

2 - Categories of journal diameters Table of journal diameter categories Journal category mark on the crankshaft

Journal diameter categories (mm)

A, G, K, R,W

D1 = 47.990 to 47.997 exclusive

B, H, L, S,Y

D2 = 47.997 inclusive to 48.003 exclusive

C, J, O, T, Z

D3 = 48.003 inclusive to 48.010

3 - Crankshaft dimensions

10021

Diameter of the journals

48 ± 0.01mm

Crankpin diameter

43.97 ± 0.01

Maximum run-out allowed on the flywheel bearing face of the flywheel

0.6mm

10A-42

ENGINE AND LOWER ENGINE ASSEMBLY Engine peripherals: Specifications

10A

X

7

21697

15197

The cylinder block bearing diameters (6) are marked with a drill hole on it (7) located above the oil filter.

The crankshaft bearing shells are fitted on the cylinder block and the bearings using the Mot. 1493-01 .

For every engine there can only be one category of crankshaft bearing diameter.

a - Direction of fitting the journal shells

3 - Table of bearing diameter classes

Positions of hole (7)

Category marking

Cylinder block bearing diameter (mm)

X = 33mm

1 or Blue

51.936 to 51.942 exclusive

X = 43mm

2 or Red

51.942 inclusive to 51.949

4 - Cylinder block gasket face bow The maximum cylinder block gasket face bow is 0.03mm . VI - BEARING SHELLS 20159

1 - Crankshaft bearing shells The engine is fitted with bearing shells without foolproofing.

Fit the grooved bearing shells on all the bearings on the cylinder block

10A-43

ENGINE AND LOWER ENGINE ASSEMBLY Engine peripherals: Specifications

10A

Fit the non-grooved bearing shells on the bearing caps. b - Matching the journal shells to the cylinder block

20158

Cylinder block bearing diameter categories

D1

D2

D3

1

C1

C2

C3

1.949 to 1.955

1.946 to 1.952

1.943 to 1.949

Yellow

Blue

Black

C4

C1

C2

1.953 to 1.959

1.949 to 1.955

1.946 to 1.952

Red

Yellow

Blue

2

Crankshaft journal diameter category

Bearing shell thickness and category

10A-44

ENGINE AND LOWER ENGINE ASSEMBLY Engine peripherals: Specifications 2 - Conrod bearing shells

17680

The engine is fitted with bearing shells without foolproofing. The con rod bearing shells are fitted using tools ( Mot. 1492 ) and ( Mot. 1492-03 ). Bearing shell width

Note: The upper and lower con rod bearing shells are not the same width. Bearing shell width: - Con rod shank bearing: 20.625 ± 0.125mm , - Con rod cap bearing: 17.625 ± 0.125mm . 3 - Crankshaft lateral shims a - Direction of fitting of lateral shims Position the lateral shim grooves facing the crankshaft . b - Position of lateral shims The lateral shims are located on crankshaft bearing no. 3 . c - Thickness of lateral shims There are two lateral shim thicknesses: 2.80mm and 2.85mm .

10A-45

10A

ENGINE AND LOWER ENGINE ASSEMBLY Standard replacement

10A

- the inlet manifold,

STANDARD EXCHANGE ENGINE

- the exhaust manifold, 1 - Preparation of the old engine for return

- the turbocharger,

Clean the engine.

- the exhaust gas recirculation valve,

Drain the oil and coolant from the old engine.

- the catalytic converter,

Secure the old engine to the stand and in the same conditions as the standard exchange engine:

- the accessories (alternator, air conditioning compressor, power-assisted steering pump),

- fit plastic plugs and covers,

- the accessories multifunction support.

- fit the cardboard cover over the whole assembly. 2 - Parts to leave on the old engine Parts to leave on the old engine or to include in the return box: - the dipstick, - the oil filter, - the oil filter seat, - the oil cooler, - the oil level sensor, - the rocker cover, - the coolant pump, - the vacuum pump, - the high-pressure pump, - the injector rail, - the injectors, - the heater plugs, - the entire timing end (crankshaft sprocket, belt, tensioner, camshaft sprocket), - the timing covers, - the crankshaft accessories pulley, - the flywheel or the drive plate, - the clutch pressure plate and driven plate, - the lifting eyes, - the cylinder head suspended mounting. 3 - Parts to remove from the old engine Parts to remember to remove from the old engine: - all the coolant system pipes, - the oil pressure switch, - the pinking sensor, - the coolant inlet hose, - the coolant outlet unit,

10A-46

ENGINE AND LOWER ENGINE ASSEMBLY Special tooling

Illustration

10A

Tool number

Tool part number

Description

Mot. 11

No longer available from the Parts Department (see Equipment required)

Crankshaft spigot bush extractor

Mot. 251-01

00 00 025 101

Dial gauge support used with Mot. 252-01

Mot. 252-01

00 00 025 201

Pressure plate for measuring piston protrusion, which is to be used with Mot. 251-01 .

68603

83812

83812-1

10A-47

ENGINE AND LOWER ENGINE ASSEMBLY Special tooling Illustration

10A

Tool number

Tool part number

Description

Mot. 445

00 00 044 500

Oil filter strap wrench.

Mot. 582-01

00 00 058 201

Flywheel king tool.

Mot. 588

00 00 058 800

Cylinder block liner clamps.

69716

loc-

99614

76666

10A-48

ENGINE AND LOWER ENGINE ASSEMBLY Special tooling Illustration

10A

Tool number

Tool part number

Description

Mot. 591-02

00 00 059 102

Magnetic hose for angle tightening.

Mot. 591-04

00 00 059 104

Cylinder Head bolt tightening gauge (1/2" drive).

Mot. 792-03

00 00 079 203

Engine plate.

77889

78181

10099

10A-49

stand

ENGINE AND LOWER ENGINE ASSEMBLY Special tooling Illustration

10A

Tool number

Tool part number

Description

Mot. 799-01

00 00 079 901

Pinion locking tool.

Mot. 856-02

00 00 085 602

Dial gauge support.

80359

14274

10A-50

ENGINE AND LOWER ENGINE ASSEMBLY Special tooling Illustration

10A

Tool number

Tool part number

Description

Mot. 923

00 00 092 300

Engine eye.

Mot. 1018

00 00 101 800

Oil change wrench

Mot. 1319-01

00 00 131 901

Crankpin height measuring tool.

Mot. 1329

00 00 132 900

Oil filter removing tool 76mm diameter.

lifting

84757

97160

10A-51

ENGINE AND LOWER ENGINE ASSEMBLY Special tooling Illustration

10A

Tool number

Tool part number

Description

Mot. 1335

00 00 133 500

Pliers for removing valve stem seals.

Mot. 1378

00 00 137 800

Support studs X and Y which can be fitted to the engine stand plate Mot. 79203 .

Mot. 1430

00 00 143 000

Pin set for timing adjustment.

98503

84900

13293

10A-52

ENGINE AND LOWER ENGINE ASSEMBLY Special tooling Illustration

10A

Tool number

Tool part number

Description

Mot. 1485-01

00 00 148 501

Tool for removing piston cooling jets.

Mot. 1489

00 00 148 900

TDC setting pin.

Mot. 1492

00 00 149 200

Tool for fitting main bearing shells.

15868

14924

15867

10A-53

ENGINE AND LOWER ENGINE ASSEMBLY Special tooling Illustration

10A

Tool number

Tool part number

Description

Mot. 1492-03

00 00 149 203

Adapter kit for fitting the conrod bearing shells.

Mot. 1493-01

00 00 149 301

Tool for fitting crankshaft bearing shells.

Mot. 1494

00 00 149 400

Tool for fitting piston cooling jets.

17584

16360

15863

10A-54

ENGINE AND LOWER ENGINE ASSEMBLY Special tooling Illustration

10A

Tool number

Tool part number

Description

Mot. 1502

00 00 150 200

Valve s p ring compression tool.

Mot. 1505

No longer available in the Parts Department, replaced by Mot. 1715

Frequency meter for belt tension.

Mot. 1511-01

00 00 151 101

Valve stem seal tool.

16088

16171

19675

10A-55

ENGINE AND LOWER ENGINE ASSEMBLY Special tooling Illustration

10A

Tool number

Tool part number

Description

Mot. 1525

00 00 152 500

High pressure pump sprocket extractor.

Mot. 1525-02

00 00 152 502

High pressure pump sprocket extractor claws.

Mot. 1566

00 00 156 600

Spanner for high pressure pipe nuts.

17588

17589

19672

10A-56

ENGINE AND LOWER ENGINE ASSEMBLY Special tooling Illustration

10A

Tool number

Tool part number

Description

Mot. 1567

00 00 151 300

Long reach EGR clip pliers.

Mot. 1573

00 00 157 300

Cylinder head support.

Mot. 1585

00 00 158 500

Tool for fitting crankshaft seal (flywheel end).

13476

17670

18896

10A-57

ENGINE AND LOWER ENGINE ASSEMBLY Special tooling Illustration

10A

Tool number

Tool part number

Description

Mot. 1586

00 00 158 600

Tool for fitting crankshaft seal (timing end).

Mot. 1632

00 00 163 200

Camshaft oil seal fitting tool (timing end).

Mot. 1638

00 00 163 800

Accessories belt tension tool.

18897

18895

21419

10A-58

ENGINE AND LOWER ENGINE ASSEMBLY Special tooling Illustration

10A

Tool number

Tool part number

Description

Mot. 1666

00 00 166 600

Balancing shaft timing tool.

Mot. 1677

00 00 167 700

Flywheel king tool.

Mot. 1714

77 11 381 714

Adapter for Mot. 1586 for crankshafts with M14 thread hole.

101777

loc-

13284

10A-59

ENGINE AND LOWER ENGINE ASSEMBLY Special tooling Illustration

10A

Tool number

Tool part number

Description

Mot. 1715

77 11 381 715

Frequency meter for belt tension.

Mot. 1729

77 11 381 729

EGR valve removal spanner.

106507

107634

10A-60

ENGINE AND LOWER ENGINE ASSEMBLY Special tooling Illustration

10A

Tool number

Tool part number

Description

Mot. 1723

77 11 381 723

Engine stand.

Mot. 1746

77 11 381 746

Offset spanner for high pressure pipes

111831

114801

10A-61

ENGINE AND LOWER ENGINE ASSEMBLY Special tooling Illustration

10A

Tool number

Tool part number

Description

Mot. 1757

77 11 381 757

EGR valve cleaning tool.

Mot. 1768

77 11 381 768

High pressure pump sprocket extractor claws.

113191

114797

10A-62

ENGINE AND LOWER ENGINE ASSEMBLY Special tooling Illustration

10A

Tool number

Tool part number

Description

Emb. 880

00 00 088 000

Pin extractor.

Emb. 1596

00 00 159 600

24mm socket.

84328

19854

10A-63

ENGINE AND LOWER ENGINE ASSEMBLY Special tooling Illustration

10A

Tool number

Tool part number

Description

Emb. 1780

77 11 381 780

Clutch centring device.

Rou. 15-01

00 01 331 601

Protective end piece.

110418

69306-1

10A-64

ENGINE AND LOWER ENGINE ASSEMBLY Equipment

Illustration

Description Engine stand.

100606

Cleaning bench.

113553

10A-65

10A

ENGINE AND LOWER ENGINE ASSEMBLY Equipment Illustration

Description Cleaning fountain.

113592

Portable crane. Load positioner.

114806

10A-66

10A

ENGINE AND LOWER ENGINE ASSEMBLY Equipment Illustration

Description Relieved thread kit.

114792

Stud extractor kit.

114790

10A-67

10A

ENGINE AND LOWER ENGINE ASSEMBLY Equipment Illustration

Description Bearing extractor kit.

114786

Torque/angle torque wrench.

113494

10A-68

10A

ENGINE AND LOWER ENGINE ASSEMBLY Equipment Illustration

10A

Description Torque wrench.

113493

Bolt tightening gauge (angular measuring type).

114798

10A-69

ENGINE AND LOWER ENGINE ASSEMBLY Equipment Illustration

10A

Description Standard 1/2" (12.7mm) square drive 8/12/14 female torx socket .

114812

Radial play measuring tape.

114814

Oil change end piece fitted with an 8mm square drive Engine oil change wrench Pair of protective gloves Protective goggles Tool for checking the valve spring loading

10A-70

ENGINE AND LOWER ENGINE ASSEMBLY Equipment Illustration

10A

Description Indelible marker Brushes with plastic or non-scratch metal (brass) bristles Compressed air gun Pressure/vacuum pump Marking gauge

114805

10A-71

ENGINE AND LOWER ENGINE ASSEMBLY Equipment Illustration

Description Sliding calliper.

114791

114783

10A-72

10A

ENGINE AND LOWER ENGINE ASSEMBLY Equipment Illustration

Description Depth gauge

114789

114782

10A-73

10A

ENGINE AND LOWER ENGINE ASSEMBLY Equipment Illustration

Description Micrometer.

114787

Body jig bench and a pair of v-blocks.

114796

10A-74

10A

ENGINE AND LOWER ENGINE ASSEMBLY Equipment Illustration

Description Magnetic holder.

114802

Multimeter.

114804

10A-75

10A

ENGINE AND LOWER ENGINE ASSEMBLY Equipment Illustration

Description Cylinder head testing tool.

12624

Toolkit for fitting valve stem seals

18077

10A-76

10A

ENGINE AND LOWER ENGINE ASSEMBLY Equipment Illustration

Description Valve spring compressor.

114803

Tweezers.

114813

10A-77

10A

ENGINE AND LOWER ENGINE ASSEMBLY Equipment Illustration

Description Cylinder head straight edge.

114784

Spanner for the high pressure pipes.

19672

10A-78

10A

ENGINE AND LOWER ENGINE ASSEMBLY Equipment Illustration

Description Crow foot spanner.

19670

Wrench with hinge for heater plugs.

19668

10A-79

10A

ENGINE AND LOWER ENGINE ASSEMBLY Equipment Illustration

10A

Description Ring for fitting pistons in the cylinder block.

113579

Tool for removing and refitting piston rings.

113581

10A-80

ENGINE AND LOWER ENGINE ASSEMBLY Equipment Illustration

10A

Description Gun for adhesive silicone seal cartridges.

114793

Standard 1/2" 22mm long socket (12.7mm square drive)

114807

10A-81

ENGINE AND LOWER ENGINE ASSEMBLY Equipment Illustration

Description Roll pin punch.

114808

10A-82

10A

ENGINE AND LOWER ENGINE ASSEMBLY Equipment Illustration

Description Male torx socket.

114810

Hexagon drive socket.

114811

10A-83

10A

ENGINE AND LOWER ENGINE ASSEMBLY Engine: Dismantling

10A

- Workshop crane,

Special tooling required

- Load positioner Mot. 1378

Mot. 792-03

Engine support studs X & Y for use with stud A for Desvil engine support

- 8mm Square drive drain plug spanner - Protective gloves.

Engine support plate for Desvil engine stand

Mot. 582-01

Flywheel locking tool.

Mot. 1677

Flywheel locking tool.

Mot. 1723

Engine support for DESVIL engine support stand.

Mot. 1018

- Male torx socket,

III - PREPARING THE ENGINE TO BE MOUNTED ON THE STAND There are two procedures for securing the engine to the stand: - by fitting tool ( Mot. 792-03 ) to the cylinder block (oil filter end), - by fitting tool ( Mot. 1723 ) to the cylinder block (flywheel end).

Sump plug tool.

1 - Fitting the engine to the stand fitted with Mot. 792-03 (oil filter end)

I - RECOMMENDATIONS FOR REPAIR

This mounting refers to the following engines only: K9K 260-270-272-700-702-704-706-710-722750-752-790. a - Engine without air conditioning

100606

IMPORTANT In order to work on the engine in complete safety, it is essential to use the new stand, or have the old stand modified by the manufacturer. When the engine is on the stand, it is essential to fit mounting pads (1) .

21861

Loosen the tensioning roller mounting bolts (4) . Remove: - the accessories belt,

II - EQUIPMENT REQUIRED

- the accessory belt tensioning roller, - the alternator mounting bolts (5) ,

- Engine stand,

- the alternator.

10A-84

ENGINE AND LOWER ENGINE ASSEMBLY Engine: Dismantling

10A

b - Engine with air conditioning

111079

Remove:

19651

- the power-assisted steering pump or dummy pulley mounting bolts (6) ,

Rotate the tensioning roller using a wrench (7) to slacken the belt.

- the power-assisted steering pump or dummy pulley.

Remove the accessories belt.

19703

111057

Remove:

Remove:

- the multifunction support mounting bolts,

- the alternator mounting bolts (8) ,

- the multifunction support.

- the alternator, - the air conditioning compressor mounting bolts (9) , - the air conditioning compressor.

10A-85

ENGINE AND LOWER ENGINE ASSEMBLY Engine: Dismantling

10A

19704

19705

Remove:

Fit the support studs (X) , (Y) of (Mot. 1378) and the support stud (A) of (Mot. 792-03) to the cylinder block.

- the auto tensioner, - the multifunction support mounting bolts, - the multifunction support.

10099

Fit the ( Mot. 792-03 ) plate onto the engine fitted with support studs by lining up: - the support stud (A) with hole 20 on the plate, - the support stud (X) with hole 33 on the plate, - the support stud (Y) with hole 32 on the plate. 19706

Fit the engine complete with plate onto the engine stand.

Remove: - the coolant hoses (10) from the coolant pump inlet pipe, - the coolant pump inlet pipe mounting bolt (11) ,

2 - Fitting the engine to the stand fitted with Mot. 1723 (flywheel end) This fitting relates to all K9K engines .

- the coolant pump inlet pipe.

10A-86

ENGINE AND LOWER ENGINE ASSEMBLY Engine: Dismantling

10A

Note: The flywheel must be removed on engines with the starter motor at the exhaust end.

20172

Remove: - the flywheel mounting bolts, - the flywheel, 19652

Fit flywheel locking tool (Mot. 582-01) or (Mot. 1677) . Remove: - the clutch pressure plate securing bolt, - the clutch pressure plate, - the friction plate.

10A-87

- the flywheel locking tool ( Mot. 582-01 ) or ( Mot. 1677 ).

ENGINE AND LOWER ENGINE ASSEMBLY Engine: Dismantling

10A

111972

111973

111832

111833

Fit the support stud of (Mot. 1723) to the cylinder block.

Fit the ( Mot. 1723 ) plate onto the engine fitted with support studs by lining up: - the support studs with holes 5, 6 and 7 on the plate (for engines with starter on the exhaust side), - the support studs with holes 1, 2, 10 and 12 on the plate (for engines with starter on the oil filter side). Fit the engine complete with plate onto the engine stand. Remove the engine wiring harness. Remove the drain plug from the sump using (Mot. 1018) or using a drain plug spanner (8mm square drive) .

10A-88

ENGINE AND LOWER ENGINE ASSEMBLY Accessories belt: Removal

10A

2 - Engine with air conditioning

I - RECOMMENDATIONS FOR REPAIR

IMPORTANT Wear protective gloves during every operation. II - EQUIPMENT REQUIRED

- Protective gloves. III - REMOVAL 1 - Engine without air conditioning

19651

Rotate the tensioning roller using a wrench (2) to slacken the belt. Remove the accessories belt.

21861

Undo the tensioning roller mounting bolts (1) . Remove: - the accessories belt, - the accessories belt tensioning roller.

19703

Remove: - the accessories belt tensioning roller mounting bolt (3) , - the accessories belt tensioning roller.

10A-89

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Removal

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790 I - TIMING GEAR REMOVAL

Special tooling required Mot. 1489

TDC locating pin.

Mot. 1430

Set of 5 crankshaft and camshaft pulley timing pins.

IMPORTANT

Mot. 582-01

Flywheel locking tool.

Wear protective gloves during every operation.

Mot. 1677

Flywheel locking tool.

Mot. 1573

Cylinder head support

II - GUIDELINES FOR REPAIRS TO THE TIMING GEAR

III - EQUIPMENT REQUIRED FOR THE TIMING GEAR

- Protective gloves, - Large screwdriver, - Allen key ( 6mm ), - Female torx socket ( 14 ). IV - REMOVAL

19654

Remove the upper timing cover by unclipping both tabs (1) .

10A-90

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Removal

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790

19654-1

Remove: - the high pressure pump position sensor (2) , - the plastic bolt (3) . Unclip the three tabs (4) . Remove the lower timing cover.

10A-91

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Removal

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790

19654-2

Remove the cylinder head suspended mounting.

19702 19650

Remove the TDC setting pin plug using a number 14 female torx socket.

10A-92

Turn the crankshaft to position the hole (5) of the camshaft pulley almost opposite the hole (6) in the cylinder head.

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Removal

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790

19650-1

19655

Insert the pin (Mot. 1430) (2) in the camshaft pulley and cylinder head holes.

Screw in the TDC setting pin (1) (Mot. 1489) .

Remove: - the camshaft pulley timing pin (Mot. 1430) , - the TDC setting pin (Mot. 1489)

14489

Turn the crankshaft clockwise (timing end) smoothly until the crankshaft comes into contact with the TDC setting pin.

10A-93

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Removal

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790

19652

Fit flywheel locking tool (Mot. 582-01) or (Mot. 1677) .

Note: For engines that have already had the flywheel removed, screw two used flywheel bolts into the crankshaft to lock it using a large screwdriver.

10A-94

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Removal

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790

19656

Remove the crankshaft accessories pulley.

10A-95

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Removal

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790

19656-1

Slacken the tensioning roller bolt (7) .

- Female torx socket.

Loosen the timing tensioning roller by turning the eccentric cam using a 6mm Allen key. Remove: - the timing belt taking care not to let the crankshaft timing sprocket fall out, - the timing tensioning roller. V - CYLINDER HEAD REMOVAL VI - GUIDELINES FOR REPAIRS TO THE CYLINDER HEAD

IMPORTANT Wear protective gloves during every operation. VII - EQUIPMENT REQUIRED FOR THE CYLINDER HEAD

- Male torx socket,

10A-96

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Removal

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790 VIII - REMOVAL

19709

Loosen the clip (11) . Remove the oil vapour rebreathing pipe (12) from the rocker cover. Undo the turbocharger oil supply pipe nut (13) . 19710

Remove: - the inner timing cover mounting bolts (10) , - the inner timing cover (by tilting the alternator if necessary).

19708

Remove: - the turbocharger oil supply pipe bolt (14) using a male torx socket, - the turbocharger oil supply pipe. 19707

Remove:

Remove:

- the clip (8) ,

- the turbocharger oil return pipe bolts (18) ,

- the air filter unit mounting bolt (9) ,

- the catalytic convertor stay bolts (16) ,

- the air filter unit.

- the exhaust flange bolts (15) on the turbocharger.

10A-97

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Removal

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790 Remove the turbocharger-catalytic converter assembly, taking care not to damage the turbocharger oil return pipe (18) .

20073

Fit the cylinder head onto the cylinder head support (Mot. 1573) . 19711

Unclip the fuel return pipe from the rocker cover (19) . Remove: - the dipstick guide tube (21) , - the rocker cover mounting bolts (20) , - the rocker cover.

19712

Remove: - the cylinder head bolts in the order specified using a female torx socket, - the cylinder head.

10A-98

Remove the cylinder head gasket from the cylinder block.

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Removal

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768 I - TIMING GEAR REMOVAL

Special tooling required Mot. 1489

TDC locating pin.

Mot. 1430

Set of 5 crankshaft and camshaft pulley timing pins.

Mot. 582-01

Flywheel locking tool.

Mot. 1677

Flywheel locking tool.

Mot. 1573

Cylinder head support

II - GUIDELINES FOR REPAIRS TO THE TIMING GEAR

IMPORTANT Wear protective gloves during every operation. III - EQUIPMENT REQUIRED FOR THE TIMING GEAR

- Protective gloves, - Large screwdriver, - Allen key ( 6mm ), - Number 14 torx socket. IV - REMOVAL

19654

Remove the upper timing cover by unclipping both tabs (1) .

10A-99

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Removal

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

19654-1

Remove: - the high pressure pump position sensor (2) , - the plastic bolt (4) . Unclip the three tabs (3) . Remove the lower timing cover.

107261

Remove the cylinder head suspended mounting.

10A-100

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Removal

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

19650

Remove the TDC setting pin plug using a female torx socket ( 14 ).

19650-1

Screw in the TDC setting pin (1) (Mot. 1489) .

14489 107270

Turn the crankshaft to position the hole (5) of the camshaft pulley almost opposite the hole (6) in the cylinder head.

10A-101

Turn the crankshaft clockwise (timing end) smoothly until the crankshaft comes into contact with the TDC setting pin.

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Removal

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

107271

19652

Insert the pin (Mot. 1430) (2) in the camshaft pulley and cylinder head holes.

Fit the flywheel locking tool (Mot. 582-01) or (Mot. 1677) .

Remove: - the camshaft pulley timing pin (Mot. 1430) ,

Note:

- the TDC setting pin (Mot. 1489) .

For engines that have already had the flywheel removed, screw two used flywheel bolts into the crankshaft to lock it using a large screwdriver.

107260

Remove the crankshaft accessories pulley.

10A-102

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Removal

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768 VIII - REMOVAL

107262 19710

Slacken the tensioning roller bolt (7) . Loosen the timing tensioning roller by turning the eccentric cam using a 6mm Allen key.

Remove:

Remove:

- the inner timing cover (by tilting the alternator if necessary).

- the timing belt,

- the inner timing cover mounting bolts (8) ,

- the timing tensioning roller. V - CYLINDER HEAD REMOVAL VI - GUIDELINES FOR REPAIRS TO THE CYLINDER HEAD

IMPORTANT Wear protective gloves during every operation.

VII - EQUIPMENT REQUIRED FOR THE CYLINDER HEAD

- Female torx socket.

112325

Disconnect the oil vapour recirculation pipe (10) . Remove: - the oil vapour recirculation valve bolts (11) , - the oil vapour recirculation valve mounting bracket bolts (9) ,

10A-103

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Removal

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768 - the oil vapour recirculation valve.

19711 112328

Remove:

Unclip the fuel return pipe from the rocker cover (15) .

- the catalytic convertor stay bolts (13) ,

Remove:

- the catalytic convertor nuts (12) on the turbocharger,

- the dipstick guide, - the rocker cover mounting bolts (16) , - the rocker cover.

- the catalytic converter.

19712

Remove: - the cylinder head bolts in the order specified using a female torx socket, - the cylinder head. 112327

Remove: - the turbocharger oil return pipe mounting bolts (14) , - the turbocharger oil return pipe.

10A-104

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Removal K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

20073

Fit the cylinder head onto the cylinder head support (Mot. 1573) . Remove the cylinder head gasket from the cylinder block.

10A-105

10A

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Removal

10A

K9K, and 732 or 764 IV - REMOVAL

Special tooling required Mot. 1489

TDC locating pin.

Mot. 1430

Set of 5 crankshaft and camshaft pulley timing pins.

Mot. 1677

Flywheel locking tool.

Mot. 1573

Cylinder head support

K9K, and 732

I - TIMING GEAR REMOVAL II - GUIDELINES FOR REPAIRS TO THE TIMING GEAR

IMPORTANT Wear protective gloves during every operation. III - EQUIPMENT REQUIRED FOR THE TIMING GEAR

112990

Remove the upper timing cover by unclipping both tabs (1) .

- Protective gloves, - Large screwdriver, - Allen key ( 6mm ), - Torx socket ( 14 ).

10A-106

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Removal

10A

K9K, and 732 or 764

19654-1

Remove the plastic bolt (4) . Unclip the three tabs (3) . Remove the lower timing cover.

112989

Remove the cylinder head suspended mounting.

10A-107

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Removal

10A

K9K, and 732 or 764

K9K, and 764

111742

Remove the cylinder head suspended mounting. 111740

Unclip the tab (8) . Rotate the timing cover (9) in the direction of the arrow. Remove the plastic bolt (10) .

19650

Remove the TDC setting pin plug using a female torx socket ( 14 ).

111741

Unclip the three tabs (11) . Remove the timing cover.

10A-108

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Removal

10A

K9K, and 732 or 764

107270

14489

Turn the crankshaft to position the hole (5) of the camshaft pulley almost opposite the hole (6) in the cylinder head.

Turn the crankshaft clockwise (timing end) smoothly until the crankshaft comes into contact with the TDC setting pin.

19650-1

109049

Screw in the TDC setting pin (1) (Mot. 1489) .

Insert the pin (Mot. 1430) (2) in the camshaft pulley and cylinder head holes. Remove: - the camshaft pulley timing pin (Mot. 1430) , - the TDC setting pin (Mot. 1489) .

10A-109

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Removal

10A

K9K, and 732 or 764

113491

Fit the flywheel locking tool (3) (Mot. 1677) .

109046

Slacken the tensioning roller bolt (7) . Slacken the timing tension wheel by turning the eccentric cam using a 6mm allen key Remove: - the timing belt, - the timing tensioning roller. V - CYLINDER HEAD REMOVAL VI - GUIDELINES FOR REPAIRS TO THE CYLINDER HEAD

107260

IMPORTANT Wear protective gloves during every operation.

Remove the crankshaft accessories pulley.

VII - EQUIPMENT REQUIRED FOR THE CYLINDER HEAD

- Female torx socket.

10A-110

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Removal

10A

K9K, and 732 or 764 VIII - REMOVAL

113479 113473

Remove:

Remove: - the turbocharger oil return pipe mounting bolts (15) ,

- the inner timing cover mounting bolts (12) , - the inner timing cover (by tilting the alternator if necessary).

- the turbocharger oil return pipe.

113475 113474

Remove:

Remove:

- the dipstick guide mounting nuts (16) ,

- the catalytic convertor mounting bolts (14) ,

- the dipstick guide, - the damper valve mounting bracket bolts (18) ,

- the catalytic convertor nuts (13) on the turbocharger,

- the damper valve mounting bolts (21) ,

- the catalytic converter.

- the damper valve,

10A-111

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Removal

10A

K9K, and 732 or 764 - the EGR valve retaining bracket (19) .

113480 113476

Remove:

Fit the cylinder head onto the cylinder head support (4) (Mot. 1573) . Remove the cylinder head gasket from the cylinder block.

- the rocker cover mounting bolts (22) , - the rocker cover.

113478

Remove: - the cylinder head bolts in the order specified using a female torx socket, - the cylinder head.

10A-112

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Dismantling

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790 - Latex protective gloves,

Special tooling required

- Indelible marker, Mot. 1566

Spanner for removing high pressure pipes.

Mot. 1746

Offset spanner for tightening high pressure pump pipes.

- Plastic bags, - Valve spring compressor, - Tweezers, - Spanner for the high pressure pipes,

Long nose pliers for EGR duct clips.

- Crow foot spanner,

Mot. 799-01

Timing gear wheel immobiliser.

- Male torx sockets.

Mot. 1502

Valve lifting tool for removing valves.

Mot. 1567

- Wrench with hinge for heater plugs,

IV - STRIPPING DOWN THE CYLINDER HEAD

I - RECOMMENDATIONS FOR REPAIR

Clean the high pressure pipe unions (see 10A, Engine and lower engine assembly, Engine: Precautions for repair, page 10A-4) .

IMPORTANT - It is essential to follow the cleanliness guidelines (see 1 0 A , Engine and lower engine assembly , Engine: Precautions for repair, page 10A-4) , - Wear latex safety gloves when using the cleaning agent, - Wear safety goggles fitted with side shields.

2 WARNING Do not blast with compressed air once the fuel circuit is open, otherwise impurities may enter the system. Use cleaning cloths only, if necessary. 19724

II - PARTS AND CONSUMABLES FOR THE REPAIRS Note:

Consumables - Set of blanking plugs, part number 77 01 206 804 , - Cleaning cloths, part number 77 11 211 707 , - Brake cleaner, part number 77 11 226 128 , - Injector cleaner, part number 77 11 224 188 . III - EQUIPMENT REQUIRED

- Protective goggles (with side shields),

10A-113

It is essential that the injector intermediate union (2) is secured when loosening the high pressure pipes.

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Dismantling

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790 - the high pressure rail mounting nuts (9) , - the rail.

Note: It is essential to match the injectors to their respective cylinders using an indelible marker.

20073

Remove the high pressure pipes using the (Mot. 1566) and (Mot. 1746) or using a pipe wrench. Fit blanking plugs: - to the high pressure pump, - to the rail, - to the injectors. 20071

Remove: - the injector clamp bolts (10) , - the injectors, - the heater plugs (11) using a hinged wrench, - the engine lifting eye (flywheel end) bolts (12) , - the engine lifting eye (flywheel end),

20072

Remove: - the high pressure pump mounting bolts (7) , - the high-pressure pump,

10A-114

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Dismantling

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790 - the engine lifting eye (timing end), - the exhaust gas recirculation pipe clips (17) using the (Mot. 1567) , - the exhaust gas recirculation pipe, - the air inlet duct mounting bolt (16) , - the inlet duct, - the exhaust gas recirculation valve mounting bolts (18) , - the exhaust gas recirculation valve, - the exhaust manifold mounting nuts (19) , - the exhaust manifold.

20070

Remove: - the vacuum pump bolts (13) , - the vacuum pump, - the cylinder head coolant outlet unit mounting bolts (14) - the cylinder head coolant outlet housing

20067

Lock the camshaft pulley using the (Mot. 799-01) Remove: - the camshaft pulley mounting nut, - the camshaft pulley.

20069

Remove: - the engine lifting eye (timing end) mounting bolts (15) ,

10A-115

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Dismantling

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790

20064-2

Remove: - the camshaft bearing cap mounting bolts (20) , - the camshaft bearing caps. Remove the camshaft.

20061

Compress the valve springs using the (Mot. 1502) (4) or using a valve spring compressor. Note:

Remove:

It is essential to match the valve tappets to their respective cylinders using an indelible marker.

- the collets using tweezers (21) , - the valve spring upper cups, - the valve springs, - the valves.

20064

Remove the valve tappets.

10A-116

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Dismantling

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768 - Tweezers,

Special tooling required

- Wrench for the high-pressure pipes, Mot. 1566

Spanner for removing high pressure pipes.

Mot. 1746

Offset spanner for tightening high pressure pump pipes.

Mot. 799-01

Timing gear wheel immobiliser.

Mot. 1502

Valve lifting tool for removing valves.

- Crow foot wrench, - Wrench with hinge for heater plugs, - Male torx sockets. IV - STRIPPING THE CYLINDER HEAD Cleaning the high-pressure pipe unions (see 10A, Engine and lower engine assembly, Engine: Precautions for repair, page 10A-4) .

I - RECOMMENDATIONS FOR REPAIR

IMPORTANT - It is essential to follow the cleanliness guidelines (see 1 0 A , Engine and lower engine assembly , Engine: Precautions for repair, page 10A-4) , - Wear latex gloves while using the cleaning product, - Wear goggles with side guards,

WARNING Do not blast with compressed air once the fuel circuit is open, otherwise impurities may enter the system. Use cleaning cloths only, if necessary.

19724

Note: II - PARTS AND CONSUMABLES FOR THE REPAIR Consumables - Set of blanking plugs, part no. 77 01 206 804 , - Cleaning cloths, part no. 77 11 211 707 , - Brake cleaner, part no. 77 11 226 128 , - Injector cleaner, part no. 77 11 224 188 , III - EQUIPMENT REQUIRED

- Protective goggles (with side guards), - Latex protective gloves, - Indelible pencil, - Plastic bags, - Valve wrench,

10A-117

When loosening the high-pressure pipes, it is essential to hold injector intermediate union (2) .

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Dismantling

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768 - the rail.

Note: It is essential to mark the injectors relative to their cylinders using an indelible pencil.

20073

Remove the high-pressure pipes using the (Mot. 1566) , (Mot. 1746) or with a pipe wrench. Fit plugs to maintain cleanliness: - on the high-pressure pump, - on the rail,

20071

- on the injectors.

Remove: - the injector bracket bolts (10) , - the injectors, - the heater plugs (11) , using a wrench with hinge, - the bolts (12) from the engine lifting eye (flywheel end), - the engine lifting eye (flywheel end),

20072

Remove: - the high-pressure pump mounting bolts (7) ,

113554

- the high-pressure pump,

Remove:

- the high-pressure pump mounting nuts (9) ,

- the mounting bolts from the vacuum pump (22) ,

10A-118

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Dismantling

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768 - the vacuum pump.

113557 113555

Remove:

Remove:

- the EGR exchanger cover bolts (13) ,

- the engine lifting eye mounting bolts (24) (timing end),

- the EGR exchanger cover,

- the engine lifting eye (timing end),

- the cylinder head coolant outlet unit bolts, (14)

- the inlet duct.

- the cylinder head coolant outlet housing Remove the camshaft pulley.

113558

Remove: 113738

Immobilise the camshaft pulley hub using the (Mot. 799-01) . Remove: - the camshaft pulley hub mounting nut (23) , - the camshaft pulley hub.

10A-119

- the six mounting bolts (26) from the EGR valve-exchanger assembly, - the EGR valve-exchanger assembly.

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Dismantling

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

113559

Loosen the mounting nut (27) from the turbocharger oil supply pipe (cylinder head end). Remove:

113561

Remove: - the mounting nuts from the exhaust manifold (30) , - the exhaust manifold.

- the mounting bolt (28) from the turbocharger oil supply pipe (turbocharger end), - the turbocharger oil supply pipe.

20064-2

Remove: - the mounting bolts (20) from the camshaft bearing caps, - the camshaft bearing caps. Remove the camshaft. 113560

Remove:

Note: It is essential to mark the valve pushrods relative to their cylinders using an indelible pencil.

- the three turbocharger mounting nuts (29) , - the turbocharger.

10A-120

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Dismantling K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

20064

Remove the valve pushrods.

20061

Compress the valve springs using the (Mot. 1502) (4) or a valve wrench. Remove: - the cotters using tweezers (21) , - the valve spring upper cups, - the valve springs, - the valves.

10A-121

10A

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Dismantling

10A

K9K, and 732 or 764 - Valve wrench,

Special tooling required

- Tweezers, Mot. 1746

Offset spanner for tightening high pressure pump pipes.

- Flat-blade and thin screwdriver, - Wrench for the high-pressure pipes,

Spanner for removing high pressure pipes.

- Crow foot wrench,

Mot. 799-01

Timing gear wheel immobiliser.

- Male torx sockets.

Mot. 1502

Valve lifting tool for removing valves.

Mot. 1566

- Wrench with hinge for heater plugs,

IV - STRIPPING THE CYLINDER HEAD

I - RECOMMENDATIONS FOR REPAIR

Cleaning the high-pressure pipe unions (see 10A, Engine and lower engine assembly, Engine: Precautions for repair, page 10A-4) .

IMPORTANT - It is essential to follow the cleanliness guidelines (see 1 0 A , Engine and lower engine assembly , Engine: Precautions for repair, page 10A-4) , - Wear latex gloves while using the cleaning product, - Wear goggles with side guards,

WARNING

113595

Do not blast with compressed air once the fuel circuit is open, otherwise impurities may enter the system. Use cleaning cloths only, if necessary.

Remove: - the mounting bolt (2) and nuts (1) from the highpressure protector, - the high-pressure protector. Clean the high-pressure pipe unions (see 10A, Engine and lower engine assembly, Engine: Precautions for repair, page 10A-4) .

II - PARTS AND CONSUMABLES FOR THE REPAIRS Consumables - Set of blanking plugs, part no. 77 01 476 857 , - Cleaning cloths, part no. 77 11 211 707 , - Brake cleaner, part no. 77 11 226 128 , - Injector cleaner, part no. 77 11 224 188 , III - EQUIPMENT REQUIRED

- Protective goggles (with side guards), - Latex protective gloves, - Indelible pencil, - Plastic bags,

10A-122

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Dismantling

10A

K9K, and 732 or 764 Fit plugs to maintain cleanliness: - on the high-pressure pump, - on the rail.

113601 113594

Remove: - the high-pressure pump mounting bolts (6) ,

Loosen the high-pressure pipe nut (high-pressure pump side) using the (Mot. 1746) (3) or a crow foot wrench.

- the high-pressure pump.

Note: Take care not to completely remove the clip from its proper position as it may become deformed.

111749 113593

Remove the high-pressure pump fuel return union (4) . Loosen the high-pressure pipe nut (high-pressure pump side) using the (Mot. 1566) (5) or a pipe wrench. Remove the high-pressure pipe between the highpressure pump and the rail.

10A-123

Push in the direction of the arrow and at (7) on the lower section of the retaining clip of the fuel return pipe on the injector using a thin, flat-blade screwdriver.

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Dismantling

10A

K9K, and 732 or 764

111751

113598

Pushing the lower bracket of the retaining clip downwards, pull out the injector fuel return pipe union.

Loosen the high-pressure pipe nuts on the injector side using the (Mot. 1566) or a pipe wrench, while holding the intermediate union with an open-jawed spanner.

Remove the fuel return pipe from the injector. Repeat the operation on the other fuel return pipe unions.

Fit the correct blanking plugs.

Fit the correct blanking plugs. Note: It is essential to mark the injectors relative to their cylinders using an indelible pencil.

113599

Loosen the high-pressure pipe nuts on the rail side using the (Mot. 1566) or a pipe wrench. 113597

Note:

Remove:

When loosening the high-pressure pipe nuts, it is essential to hold the injector intermediate union with a wrench (9) .

- the mounting bolts from the engine lifting eye (12) (timing end), - the engine lifting eye, - the high-pressure pump mounting nuts (11) , - the high-pressure rail, - the injector bracket bolts (10) , - the injectors.

10A-124

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Dismantling

10A

K9K, and 732 or 764 - the EGR exchanger cover, - the cylinder head coolant outlet unit bolts (14) , - the cylinder head coolant outlet unit Remove the camshaft pulley.

113596

Remove the heater plugs using a wrench with hinge,

113738

Immobilise the camshaft pulley hub using the (Mot. 799-01) . Remove: - the mounting nut (23) from the camshaft pulley hub, - the camshaft pulley hub. 113554

Remove: - the mounting bolts from the vacuum pump (22) , - the vacuum pump.

113557

Remove: - the mounting bolts (24) from the engine lifting eye (timing end), 113555

Remove:

- the engine lifting eye (timing end),

- the EGR exchanger cover bolts (13) ,

- the inlet duct.

10A-125

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Dismantling

10A

K9K, and 732 or 764

113558

Remove: - the six mounting bolts (26) from the EGR valve-exchanger assembly, - the EGR valve-exchanger assembly.

113560

Remove: - the three turbocharger mounting nuts (29) , - the turbocharger.

113559

Loosen the mounting nut (27) from the turbocharger oil supply pipe (cylinder head end). Remove: 113561

- the mounting nut (28) from the turbocharger oil supply pipe (turbocharger end),

Remove:

- the turbocharger oil supply pipe.

- the mounting nuts from the exhaust manifold (30) , - the exhaust manifold.

10A-126

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Dismantling

10A

K9K, and 732 or 764

113563

Remove:

113564

Remove the valve pushrods.

- the mounting bolts (20) from the camshaft bearing caps, - the camshaft bearing caps.

113565

Remove the camshaft.

Note: It is essential to mark the valve pushrods relative to their cylinders using an indelible pencil.

10A-127

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Dismantling K9K, and 732 or 764

113566

113567

Compress the valve springs using the (Mot. 1502) (4) or a valve wrench. Remove: - the cotters using tweezers (21) , - the valve spring upper cups, - the valve springs, - the valves.

10A-128

10A

ENGINE AND LOWER ENGINE ASSEMBLY Upper engine: Cleaning

10A

- Carburettor cleaner, part no. 77 11 171 437 ,

Special tooling required Mot. 1729

Pin wrench for removing the EGR valve.

Mot. 1757

EGR solenoid valve actuator.

III - EQUIPMENT REQUIRED

- Protective goggles, - Protective gloves, - Wooden spatula,

I - RECOMMENDATIONS FOR REPAIR

- Brushes with plastic or non-scratch metal (brass) bristles, IMPORTANT

- Compressed air gun,

Do not scratch the aluminium sealing surfaces.

- Cleaning fountain,

Wear goggles.

- Cleaning bench.

Wear gloves during the operation. IV - CLEANING THE UPPER ENGINE WARNING

Apply the Décapjoint product to the sections to be cleaned.

Do not allow this product to drip on to the paintwork.

Leave for around ten minutes.

Clean the cylinder head carefully to prevent foreign bodies from entering the oil supply and return galleries. Failure to follow this advice could lead to the blocking of the various oil inlet galleries, which would quickly result in engine damage. When cleaning parts, it is essential to not knock the parts against each other, or their mating faces may be damaged and therefore their adjustments may be altered, which could damage the engine. Cleaning recommendation for the EGR solenoid valve : - do not wet the electrical part of the solenoid valve with the cleaning product. - keep the solenoid valve tilted with the connector at the top. - only use brushes with plastic or non-corrosive metal (brass) bristles. - cleaning using hard or corrosive tools (e.g: screwdriver) may damage the valves or their shafts, and lead to leaking valves with a consequent loss of power. Or a loss of the upper valve leading to destruction of the engine. II - PARTS AND CONSUMABLES FOR THE REPAIR Consumables - Décapjoint, part no. 77 01 405 952 , - Grey sanding pad, part no. 77 01 405 943 .

10A-129

Remove residues with a wooden spatulas Finish cleaning the parts using a grey polishing pad.

ENGINE AND LOWER ENGINE ASSEMBLY Upper engine: Cleaning

10A

107634

Fully insert the spigots (1) of tool (Mot. 1729) in the mounting holes of the EGR solenoid valve.

113553

113592

Wash the cylinder head parts using a cleaning fountain or a heated cleaning bath. V - CLEANING THE EGR SOLENOID VALVE

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 728 or 729 or 750 or 752 Place the exhaust gas recirculation unit in a vice with clamping jaws. Remove the EGR solenoid valve mounting bolts.

10A-130

Remove the EGR solenoid valve, with small rotating movements to detach the EGR solenoid valve from its housing.

ENGINE AND LOWER ENGINE ASSEMBLY Upper engine: Cleaning

10A

113190

113191

Connect: - the connector (4) of the (Mot. 1757) to the solenoid valve, - the adaptor (5) of the (Mot. 1757) to a power supply. Briefly press the button (6) to open the solenoid valve valves.

Note:

113186

Protect the vent holes (2) of the solenoid valve using adhesive tape (3) . Freely wet the mechanical part only of the EGR solenoid valve with cleaning fluid, while brushing the EGR solenoid valve for 1 min .

Note: The EGR solenoid valve actuator tool can be used to check the solenoid valve. An indicator will sound in case of: - incorrect connection of the tool to the solenoid valve, - solenoid valve short circuit, - break in the solenoid valve circuit.

10A-131

In the open position (with power to the solenoid valve) the warning light (7) is on.

ENGINE AND LOWER ENGINE ASSEMBLY Upper engine: Cleaning

113189

10A

113186

Clean the mechanical part of the solenoid valve by simultaneously scrubbing and drenching with cleaning product for 2 min , paying particular attention to:

Clean the mechanical section of the solenoid valve (during the open/close cycle) by scrubbing and drenching with cleaning product (simultaneously), paying attention to:

- the valve seats,

- the valve seats,

- the surfaces of the valves,

- the surfaces of the valves,

- the shaft guide of the valves.

- the shaft guide of the valves.

Briefly press the button (6) to close the solenoid valve valves.

Briefly press the button (6) to open the solenoid valve valves.

Start an open/close cycle of the solenoid valve using the (Mot. 1757) keeping the button pressed (6) .

10A-132

ENGINE AND LOWER ENGINE ASSEMBLY Upper engine: Cleaning

10A

113188

113186

Scrub the upper valve (9) over its entire surface and circumference.

Clean the mechanical part of the solenoid valve (during the open/close cycle) by scrubbing and drenching with cleaning product (simultaneously), paying attention to:

Scrub the part of the lower valve (8) which is accessible through the window (10) .

- the valve seats,

Hold the upper valve (9) .

- the surfaces of the valves,

Quarter turn the valve. Scrub the part of the lower valve (8) which is accessible through the window (10) . Continue until the valve has been cleaned over its entire circumference. Briefly press the button (6) to close the solenoid valve valves. Run the open/close cycle of the solenoid valve twice using the (Mot. 1757) keeping the button pressed (6) .

10A-133

- the shaft guide of the valves. Check there are no bristles from the brush in the solenoid valve. Briefly press the button (6) to open the solenoid valve valves.

ENGINE AND LOWER ENGINE ASSEMBLY Upper engine: Cleaning

113187

Blow the solenoid valve dry using a compressed air gun. Briefly press the button (6) to close the solenoid valve valves. Remove the adhesive tape from the vent holes of the solenoid valve.

10A-134

10A

ENGINE AND LOWER ENGINE ASSEMBLY Upper engine: Checking

10A

III - CHECKING THE UPPER ENGINE

Special tooling required Mot. 588

Cylinder block liner clamps.

Mot. 251-01

Dial gauge support.

Mot. 252-01

Dial gauge support thrust plate.

1 - Check height of cylinder head

I - RECOMMENDATIONS FOR REPAIR

H

WARNING Parts should be clean before examining and testing them. II - EQUIPMENT REQUIRED

- Torque wrench and cylinder head bolt tightening gauge (angular measuring type), 21702

- Torque/angle wrench,

Measure the height of the cylinder head (H) which should be 127 mm using a mortice gauge.

- Radial play measuring tape. - Tool for checking the valve spring loading - Pressure/vacuum pump

2 - Checking the cylinder head gasket face

- Sliding calliper,

Use a cylinder head adjuster and set of feeler gauges to check the gasket face bow.

- Depth gauge

Maximum distortion: 0.05 mm

- Mortice gauge,

The cylinder head cannot be adjusted.

- Micrometer, - Dial gauge, - Body jig bench and a pair of v-blocks. - Magnetic holder, - Multimeter, - The valve stem seal fitting kit, - The cylinder head test tools, - Set of shims, - Cylinder head rule.

10A-135

ENGINE AND LOWER ENGINE ASSEMBLY Upper engine: Checking

10A

3 - Checking the cylinder head seal

103363

Test the cylinder head for possible cracks with the cylinder head test kit. For the use of the cylinder head test unit (see Technical Note 2781E ).

10A-136

ENGINE AND LOWER ENGINE ASSEMBLY Upper engine: Checking 4 - Cam height checks

10A

5 - Check the camshaft bearing diameters

102772

Using a micrometer, measure the external diameter of each camshaft bearing: - bearing nos. 1,2,3,4,5: 24.9895 ± 0.0105 mm , - bearing no. 6: 27.9895 ± 0.0105 mm .

103149

D

H

102768

102771

Position camshaft bearings 2 and 4 on the v-blocks.

Using a micrometer, measure the internal diameter of each cylinder head bearing:

Using a micrometer, measure the height of the cams (H) which should be:

- bearings No.1, 2, 3, 4, 5: 25.05 ± 0.01 mm ,

- Inlet: 44.015 ± 0.03 mm ,

- bearing No.6: 28.05 ± 0.01 mm .

- Exhaust: 44.595 ± 0.03 mm .

6 - Checking camshaft end play Refit the camshaft.

10A-137

ENGINE AND LOWER ENGINE ASSEMBLY Upper engine: Checking

10A

113562

Refit the camshaft bearing caps (observing their original positions, bearing No. 1 (5) engine flywheel end). 20063

Place the (Mot. 588) on the cylinder head, fixing it using the rocker cover bolt and a cross piece with dimensions as follows: - external diameter 18 mm , - internal diameter 9 mm , - height 15 mm . Fix the magnetic holder to the cylinder head. Using a dial gauge, measure the longitudinal gap which should be between 0.08 and 0.178 mm . Remove:

20064-2

- the camshaft bearing caps,

Tighten to torque and in order the crankshaft bearing cap mounting bolts (11 Nm) .

- the camshaft. 7 - Checking the camshaft diametric clearance Remove any oil that may be on the camshaft bearings and the camshaft bearing caps. Refit the camshaft.

10A-138

ENGINE AND LOWER ENGINE ASSEMBLY Upper engine: Checking

10A

113563

Tighten to torque and in order the crankshaft bearing cap mounting bolts (11 Nm) . Remove: - the camshaft bearing caps,

114814

Cut pieces of measuring wire (13) .

- the camshaft.

Place the wire in the camshaft shaft.

Measure the flattening of the clearance measuring wire using the packaging paper (14) . Check the value of the diametric clearance which should be between 0.04 and 0.081 mm .

Note:

Clean any traces of measuring wire off the camshaft and the camshaft bearing caps.

Do not allow the camshaft to turn during the operation in order to avoid distorting the measurement.

8 - Checking the radial deviation of the camshaft

113562

Refit the camshaft bearing caps (observing their original positions, bearing No. 1 (5) engine flywheel end).

103148

Position camshaft bearings 2 and 4 on the v-blocks. Position a dial gauge vertically on camshaft bearing 3.

10A-139

ENGINE AND LOWER ENGINE ASSEMBLY Upper engine: Checking

10A

Turn the camshaft by hand. Measure the radial deviation which should not be in excess of 0.05 mm . 9 - Checking the valves

18077

102778

Measure the valve stem diameter (D) at (X1) :

Insert (without forcing) the valve in the guide tube (15) (with the same diameter as the valve) of the valve stem seal fitting set (16) to check:

- Inlet: 5.977 ± 0.008 mm at (X1) = 41 mm , - Exhaust: 5.963 ± 0.008 mm at (X1) = 41 mm ,

- that the valve is not twisted,

Measure the valve head diameter (D) : - Inlet: 33.5 ± 0.12 mm ,

- that the end of the valve (wedge end) is not strained.

- Exhaust: 29 ± 0.12 mm . Measure the valve length (L) : - Inlet: 100.95 ± 0.22 mm , - Exhaust: 100.75 ± 0.22 mm .

10 - Checking the clearance between the valve and the guide

Measure the seat angle (A) : The clearance between the valve and the guide can be checked in two different ways.

- Inlet: 90˚ , - Exhaust: 90˚ . Thickness (T) of the valve head: - Inlet: 1 mm , - Exhaust: 1 mm .

H 102777

Press the head of the valve to a height (H) of 25mm , then, using a dial gauge, take the measurement in the direction of the arrows, keeping to an angle of

10A-140

ENGINE AND LOWER ENGINE ASSEMBLY Upper engine: Checking 90˚ to the camshaft shaft. The clearance between the valve and the guide is equal to half the measured value.

10A

12 - Checking the valve springs

102782

Or using a micrometer measure the external diameter of the valve stem and interior diameter of the valve guide.

102776

Checking the calibration of the springs.

Clearance between the valve and the valve guide should be:

Length under load: - 230 ± 12 N : 33.80 mm ,

- Inlet: 0.02 to 0.05 mm ,

- 500 ± 23 N : 24.80 mm .

- Exhaust: 0.03 to 0.063 mm .

Length of coiled seals: 23.40 mm . Wire diameter: 3.45 mm .

11 - Valve recess

Internal diameter: - at the base of the spring 18.80 ± 0.2 mm , - at the top of the spring 14.10 ± 0.2 mm , External diameter: - at the base of the spring 25.70 ± 0.2 mm , - at the top of the spring 21 ± 0.2 mm ,

20062

Check the valve recess using (Mot. 251-01) , (Mot. 252-01) and a dial gauge, which should be 0 ± 0.07 mm .

10A-141

ENGINE AND LOWER ENGINE ASSEMBLY Upper engine: Checking

10A

102774

103157

Check that the perpendicularity of the spring is not in excess of 1.2 mm .

Measure the external diameter of the tappet using a micrometer 34.975 ± 0.01 mm .

13 - Valve pushrod

103156

Check the condition of the tappet (worn or coating cracked (17) ).

10A-142

ENGINE AND LOWER ENGINE ASSEMBLY Upper engine: Checking

10A

15 - Heater plugs

14 - Turbocharger

Check the resistance of the plug using a multimeter. The resistance should be 0.6 ω .

21869

110748

Check the turbocharger pressure valve. Use a magnetic holder fitted with a dial gauge or a set of shims positioned at the end of the regulating valve stem or between the regulating valve stem and the valve guard (in the axis of the stem). Progressively apply pressure or a vacuum to the regulation valve using a pressure/vacuum pump (see 10A, Engine and lower engine assembly, Upper engine: Specifications, page 10A-28) .

10A-143

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790 Tightening torquesm

Special tooling required Mot. 1511-01

Valve stem seal fitting tool adapter.

Mot. 1335

Pliers for removing valve stem seals.

Mot. 1502

Valve lifting tool for removing valves.

Mot. 799-01

Timing gear wheel immobiliser.

Mot. 856-02

Dial gauge support.

Mot. 252-01

Dial gauge support thrust plate.

Mot. 1632

Tool for fitting PTFE camshaft seal

Mot. 1567

Long nose pliers for EGR duct clips.

Mot. 1746

Offset spanner for tightening high pressure pump pipes.

Mot. 1566

Spanner for removing high pressure pipes.

Tightening torquesm

the engine lifting eye mounting bolts (timing end)

M8 to 21 ± 2.1 Nm or M6 to 10 ± 1 Nm

the cylinder head coolant outlet unit mounting bolts

11 ± 1.1 Nm

the vacuum pump bolts

21 ± 2.1 Nm

the heater plugs

15 ± 1.5 Nm

the engine lifting eye mounting bolts (flywheel end)

13 ± 1.3 Nm

the injector bracket bolts

28 ± 2.8 Nm

the high-pressure pump mounting bolts

21 ± 2.1 Nm

injector rail mounting nuts

28 ± 2.8 Nm

the pump-rail highpressure pipe nuts

24 ± 2.4 or 38 ± 3.8 Nm

the rail-injectors highpressure pipe nuts

24 ± 2.4 or 38 ± 3.8 Nm

I - RECOMMENDATIONS FOR REPAIR

the crankshaft bearing cap mounting bolts

11 ± 1.1 Nm

the camshaft pulley mounting stud

12 ± 2 Nm

It is essential to follow the cleanliness guidelines (see Engine: Precautions during repair ).

the crankshaft bearing cap mounting bolts

11 ± 1.1 Nm

Wear latex gloves while using the cleaning product.

the mounting nut for the camshaft pulley

30 ± 3 Nm + 86°° ± 6°°

exhaust manifold mounting nuts

26 ± 2.6 Nm

EGR recirculation unit mounting bolts

21 ± 2.1 Nm

the inlet duct mounting bolt

21 ± 2.1 Nm

IMPORTANT

10A-144

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790

WARNING Before fitting a new high-pressure pipe, lightly lubricate the nut threads with oil from the applicator provided with the new part. Be careful not to allow oil into the high-pressure pipe. Do not lubricate high-pressure pipes supplied without an applicator; these pipes are self-lubricating. Do not remove the blanking plugs from each component until the last moment. Do not blast with compressed air once the fuel circuit is open, otherwise impurities may enter the system. Tighten to torque ( 38 ± 3.8 Nm ) the pump-rail and rail-injectors high-pressure pipes, part nos.: - 77 01 207 025

20960

- 77 01 207 026 - 77 01 207 027 - 77 01 207 028 - 77 01 207 029 For the high-pressure pipes with the remaining part nos, tighten to a torque of ( 24 ± 2.4 Nm ). Applying excess sealant could cause it to be squeezed out when parts are tightened. A mixture of sealant and fluid could damage certain components (engine, radiator, etc.) The sealing surfaces must be clean, dry and free from grease (avoid finger marks). The gaskets must always be replaced. The camshaft pulley mounting stud must be replaced if it comes loose as the camshaft pulley is removed. Do not grease the valve stem seals.

II - PARTS AND CONSUMABLES FOR THE REPAIR Parts always to be replaced - Camshaft pulley nut, - Camshaft seal (timing end), - The injector heat protection washers, - High-pressure pipes, - The vacuum pump seal,

10A-145

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790 - The cylinder head coolant outlet unit seal, - The exhaust manifold gasket, - The inlet tube gasket, - The exhaust gas recirculation pipe, - The EGR solenoid valve seal, - Valve stem seals Consumables - Loctite 518, part no. 77 01 421 162 , - Degreasing agent, part no. 77 11 224 559 . III - EQUIPMENT REQUIRED

- Latex protective gloves, - high-pressure pipes valve wrench, - Tweezers, - Wrench for the high-pressure pipes, - Crow foot wrench, - Wrench with hinge for heater plugs, - Roller-type stud removal tool - The valve stem seal fitting kit, - Dial gauge, - Magnetic holder, - Torque/angle wrench, - Torque wrench - Cylinder head bolt tightening gauge (angular measuring type).

10A-146

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790 IV - REASSEMBLING THE CYLINDER HEAD

18077 15738

Note: Before removing the valve stem seals, it is essential to note the position (H) of the old seals on the inlet side, then the exhaust side as the fitting dimension of the seals may be different between the inlet and the exhaust. Fit a valve. Compare dimension (H) of an old seal with the cylinder head using the (Mot. 1511-01) (4) or the valve stem seal fitting kit (5) .

19675

Note: The internal diameter of the pushrod (1) should be identical to that of the valve; In addition, the bottom of the pushrod must be snug against the metal upper section of the valve stem seal.

10A-147

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790 Apply engine oil to the inside of the valve guide.

15738-1 15739

Place the pushrod (1) over the valve stem seal. Place the valve in the cylinder head.

17999

Fit the guide tube (2) above the pushrod until it comes into contact with the cylinder head. Lock the pushrod with the wheel (3) . Remove the guide tube-pushrod assembly, being careful not to loosen the wheel. Remove: - the valve, - the valve stem seals (inlet end then exhaust end) using the (Mot. 1335) .

10A-148

15739-1

Place the valve insert (6) on the valve stem (the diameter of the valve insert should be identical to that of the valve stem).

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790

15739-2

Keep the valve pressed against its seat. Mount the valve stem seal (not lubricated) over the valve insert. Push the valve stem seal until it goes past the valve insert. 15739-4

Fit the guide tube-pushrod assembly on the valve stem seal. Push home the valve stem seal by gently striking the pushrod with the palm of the hand, until the guide tube makes contact with the cylinder head. Repeat the preceding operations on all the inlet and exhaust valves.

15739-3

Remove the valve insert.

10A-149

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790

16051-1

16084

Refit the cotters using tweezers.

Refit: - the valve springs, positioning the conical part (7) of the spring at the top, - the valve spring upper cups (8) ,

20064

Refit the pushrods observing their original position. Oil the valve pushrods and the camshaft bearings with engine oil.

113566

Compress the valve springs using the (Mot. 1502) or a valve wrench.

10A-150

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790

113565

Refit the camshaft.

20067

Refit: - the camshaft pulley, - the old exhaust camshaft pulley mounting nut. Tighten to torque the mounting nut for the camshaft pulley (15 ± 1.5 Nm) , blocking the camshaft pulley with the (Mot. 799-01) . Check and adjust the valve clearances following the procedure below. 113562

Refit the camshaft bearing caps (observing their original positions, bearing No. 1 (10) engine flywheel end).

86911

Position the cylinder valves (1) in the end of exhaust stroke, beginning of inlet stroke position.

20064-2

Tighten to torque and in order the crankshaft bearing cap mounting bolts ( 11 ± 1.1 Nm ) .

10A-151

Measure the valve clearance (X) of the cylinder (4) using a set of shims. - inlet valve clearance 0.20 mm , - exhaust valve clearance 0.40 mm ,

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790 Note the clearance values. Repeat the above operations on the other cylinders: - position cylinder No. 3 at an angle and measure the clearance of cylinder No. 2 , - position cylinder No. 4 at an angle and measure the clearance of cylinder No. 1 , - position cylinder No. 2 at an angle and measure the clearance of cylinder No. 3 , Compare the values noted with the specified values. Remove: - the nut from the camshaft pulley, - the camshaft pulley, - the camshaft bearing caps, - the camshaft, - the pushrod(s) which are outside of permitted tolerance values, noting their original position. Undertake the following installation to determine the class of thickness of the valve pushrod.

14678-1

Lift the top piece (17) of the dial gauge (without changing the position of the dial gauge-magnetic holder assembly). Mount the valve pushrod (18) to be measured on the plate of the (Mot. 252-01) . Take the measurement (Y) . Repeat the preceding operations for the other valve pushrods to be measured. Refit the new valve pushrod(s) in the cylinder head. Check that the camshaft pulley mounting stud has not come loose. If so, the stud must be replaced following the procedure described below. Place the camshaft in a vice fitted with a clamping jaw.

14678

Screw the extension piece (13) of the (Mot. 856-02) to a dial gauge (15) . Fix the dial gauge (15) to a magnetic holder (16) . Mount the dial gauge-magnetic holder assembly on the plate (14) of the tool (Mot. 252-01) . Calibrate the dial gauge.

10A-152

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790

113565

Refit the camshaft.

109050

Remove the piston rings using a roller-type stud removal tool (19) . Clean the threaded hole of the camshaft carefully to prevent foreign bodies from entering the latter. Fit the new stud on the camshaft (precoated section (20) on the camshaft side). Tighten to torque the camshaft pulley mounting stud ( 12 ± 2 Nm ) using a roller-type stud removal tool (19) . Oil the top of the valve pushrods and the camshaft bearings with engine oil.

113562

Refit the camshaft bearing caps (observing their original positions, bearing No. 1 (22) engine flywheel end).

20064-1

Degrease the surfaces of the camshaft bearing gaskets nos. 1 and 6 (21) using degreaser.

20064-2

Apply four beads of LOCTITE 518 of a width of 1 mm to camshaft bearings nos. 1 and 6 (21) .

Tighten to torque and in order the crankshaft bearing cap mounting bolts ( 11 ± 1.1 Nm ) .

10A-153

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790 Apply degreaser to: - the end of the camshaft at the timing end, - the housing on the cylinder head of the camshaft gasket.

21687-2

Position the cover (25) and collar nut (2 4) of the (Mot. 1632) . 21687

Screw the shoulder stud (23) of the (Mot. 1632) onto the mounting stud of the camshaft pulley.

21687-3

Screw on the collar nut until the cover touches the cylinder head. 21687-1

Remove:

Refit the camshaft gasket. - the collar nut, - the cap, - the shoulder stud.

10A-154

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790

20068

Refit:

20069

Tighten to torque and in order the exhaust manifold mounting nuts ( 26 ± 2.6 Nm ) .

- the camshaft pulley, - the new camshaft pulley mounting nut. Tighten to torque and angle the mounting nut for the camshaft pulley ( 30 ± 3 Nm + 86°° ± 6°° ) , blocking the camshaft pulley with the (Mot. 799-01) . Using degreaser, degrease the surfaces of the exhaust manifold and cylinder head gaskets at the exhaust end. Refit: - a new turbocharger-exhaust manifold gasket, - the exhaust manifold, - the exhaust manifold mounting nuts.

20069

Refit: - the EGR recirculation unit (26) without tightening the bolts, - the exhaust gas recirculation pipe (27) , - the mounting clips of the exhaust gas recirculation pipe. Tighten the clips of the exhaust gas recirculation pipe using the (Mot. 1567) .

10A-155

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790 Tighten to torque the EGR recirculation unit mounting bolts ( 21 ± 2.1 Nm ) . Refit: - a new seal on the inlet duct, - the inlet duct (28) , - the engine lifting eye (29) (timing end). Tighten to torque: - the inlet duct mounting bolt ( 21 ± 2.1 Nm ) , - the engine lifting eye mounting bolts (timing end) ( M8 to 21 ± 2.1 Nm or M6 to 10 ± 1 Nm ) . Using degreaser, degrease the seal surfaces where the vacuum pump enters and at the cylinder head coolant outlet.

19724

Note: If one or more injectors are replaced, note the alphanumeric code (C2I) (34) and the number of the cylinder on which it is fitted.

20070

Refit: - the cylinder head coolant outlet unit (30) fitted with a new seal, - the vacuum pump (31) fitted with a new seal. Tighten to torque: - the cylinder head coolant outlet unit mounting bolts ( 11 ± 1.1 Nm ) , - the vacuum pump bolts ( 21 ± 2.1 Nm ) . Refit the heater plugs. Tighten to torque the heater plugs ( 15 ± 1.5 Nm ) using a wrench with hinge.

10A-156

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790

20071

20072

Refit:

Refit:

- engine lifting eye (flywheel end),

- the high-pressure pump,

- the new heat protection washers,

- the injector rail (without tightening the nuts) .

- the injectors (observing their positions),

Tighten to torque the high-pressure pump mounting bolts ( 21 ± 2.1 Nm ) .

- the injector brackets. Tighten to torque: - the engine lifting eye mounting bolts (flywheel end) ( 13 ± 1.3 Nm ) (32) , - the injector bracket bolts ( 28 ± 2.8 Nm ) (33) .

10A-157

Note: Do not lubricate high-pressure pipes supplied without an applicator; these pipes are selflubricating.

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790

20960

19723

Lightly lubricate the nut threads with oil from the applicator supplied with the new part, taking care not to insert it in the pipe.

Fit the new clip provided with the new high-pressure pipe. Tighten to torque the injector rail mounting nuts ( 28 ± 2.8 Nm ) .

Note: Completely tighten one high-pressure pipe before moving to the next one. Tighten to torque and in order (according to the part no. of the pipe) the pump-rail high-pressure pipe nuts ( 24 ± 2.4 or 38 ± 3.8 Nm ) : - high-pressure pump side, using the (Mot. 1746) or a crow foot wrench, - injector rail side, using the (Mot. 1746) or a crow foot wrench, Tighten to torque and in order (according to the part no. of the pipe) the rail-injectors high-pressure pipe nuts ( 24 ± 2.4 or 38 ± 3.8 Nm ) : 20073

- injector side using the (Mot. 1566) or with a wrench for high-pressure pipes.

Insert the high-pressure pipe olive in the injector high-pressure inlet taper.

- injector rail side, using the (Mot. 1566) or a crow foot wrench,

Insert the high-pressure pipe olive in the rail highpressure outlet taper. Finger tighten the high-pressure pipe nuts, starting with the one located on the injector end. Lightly tighten the nuts of the high-pressure pipes.

10A-158

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768 Tightening torquesm

Special tooling required Mot. 1511-01

Valve stem seal fitting tool adapter.

EGR valve-exchanger mounting bolts

25 ± 2.5 Nm

Mot. 1335

Pliers for removing valve stem seals.

mounting bolts of the exhaust gas recirculation pipe

35 ± 3.5 Nm

Mot. 1502

Valve lifting tool for removing valves.

engine lifting eye mounting bolts (timing end)

21 ± 2.1 Nm

camshaft pulley hub nut

30 ± 3 Nm + 86˚ ± 6˚

the cylinder head coolant outlet bolt

11 ± 1.1 Nm

the EGR exchanger cover mounting bolt

12 ± 1.2 Nm

vacuum pump mounting bolts

21 ± 2.1 Nm

the heater plugs

15 ± 1.5 Nm

the engine lifting eye mounting bolts (flywheel end)

13 ± 1.3 Nm

the injector bracket bolts

28 ± 2.8 Nm

high-pressure pump mounting bolts

21 ± 2.1 Nm

injector rail mounting nuts

28 ± 2.8 Nm

the pump-rail highpressure pipe nuts

24 ± 2.4 or 38 ± 3.8 Nm

the rail-injectors highpressure pipe nuts

24 ± 2.4 or 38 ± 3.8 Nm

Mot. 799-01

Timing gear wheel immobiliser.

Mot. 856-02

Dial gauge support.

Mot. 252-01

Dial gauge support thrust plate.

Mot. 1632

Tool for fitting PTFE camshaft seal

Mot. 1567

Long nose pliers for EGR duct clips.

Mot. 1746

Offset spanner for tightening high pressure pump pipes.

Mot. 1566

Spanner for removing high pressure pipes.

Tightening torquesm the crankshaft bearing cap mounting bolts

11 ± 1.1 Nm

the camshaft pulley mounting stud

12 ± 2 Nm

the crankshaft bearing cap mounting bolts

11 ± 1.1 Nm

exhaust manifold mounting nuts

26 ± 2.6 Nm

turbocharger mounting nuts

26 ± 2.6 Nm

the turbocharger oil supply pipe mounting bolt (turbocharger end)

23 ± 2.3 Nm

the turbocharger oil supply pipe mounting nut (cylinder head end)

collar nut 35 ± 3.5 Nm or no collar nut 23 ± 2.3 Nm

I - RECOMMENDATIONS FOR REPAIR

IMPORTANT

10A-159

It is essential to follow the cleanliness guidelines (see Engine: Precautions during repair ). Wear latex gloves while using the cleaning product.

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

WARNING Before fitting a new high-pressure pipe, lightly lubricate the nut threads with oil from the applicator provided with the new part. Be careful not to allow oil into the high-pressure pipe. Do not lubricate high-pressure pipes supplied without an applicator; these pipes are self-lubricating. Do not remove the blanking plugs from each component until the last moment. Do not blast with compressed air once the fuel circuit is open, otherwise impurities may enter the system. Tighten to torque ( 38 ± 3.8 Nm ) the pump-rail and rail-injectors high-pressure pipes, part nos.: - 77 01 207 025

20960

- 77 01 207 026 - 77 01 207 027 - 77 01 207 028 - 77 01 207 029 For the high-pressure pipes with the remaining part nos, tighten to torque ( 24 ± 2.4 Nm ). Applying excess sealant could cause it to be squeezed out when parts are tightened. A mixture of sealant and fluid could damage certain components (engine, radiator, etc.) The sealing surfaces must be clean, dry and free from grease (avoid finger marks). The gaskets must always be replaced. The camshaft pulley mounting stud must be replaced if it comes loose as the camshaft pulley is removed. Do not grease the valve stem seals.

II - PARTS AND CONSUMABLES FOR THE REPAIR Parts always to be replaced - Camshaft pulley nut, - Camshaft seal (timing end), - The injector heat protection washers, - High-pressure pipes, - The EGR exchanger cover seal, - The vacuum pump seal,

10A-160

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768 - The cylinder head coolant outlet unit seal, - The exhaust manifold gasket, - The turbocharger seal - The inlet duct gasket, - The exhaust gas recirculation pipe, - The EGR solenoid valve seal, - Valve stem seals Consumables - Loctite 518 part no. 77 01 421 162 , - High-resistance bolt locking product, part no. 77 11 230 112 , - Degreasing agent, part no. 77 11 224 559 . III - EQUIPMENT REQUIRED

- Latex protective gloves, - Valve wrench, - Tweezers, - Wrench for the high-pressure pipes, - Crow foot wrench, - Wrench with hinge for heater plugs, - Roller-type stud removal tool - Oil can, - The valve stem seal fitting kit, - Dial gauge, - Magnetic holder, - Torque/angle wrench, - Torque wrench - Cylinder head bolt tightening gauge (angular measuring type).

10A-161

10A

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768 IV - REASSEMBLING THE CYLINDER HEAD

18077 15738

Note: Before removing the valve stem seals, it is essential to note the position (H) of the old seals on the inlet side, then the exhaust side, as the fitting dimensions of the seals may be different between the inlet and the exhaust. Fit a valve. Compare dimension (H) of an old seal with the cylinder head using the (Mot. 1511-01) (4) or the valve stem seal fitting kit (5) .

19675

Note: The internal diameter of the pushrod (1) should be identical to that of the valve; In addition, the bottom of the pushrod must be snug against the metal upper section of the valve stem seal.

10A-162

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768 Apply engine oil to the inside of the valve guide.

15738-1 15739

Place the pushrod (1) over the valve stem seal. Place the valve in the cylinder head.

17999

Fit the guide tube (2) above the pushrod until it comes into contact with the cylinder head. Lock the pushrod with the wheel (3) . Remove the guide tube-pushrod assembly, being careful not to loosen the wheel. Remove: - the valve, - the valve stem seals (inlet end then exhaust end) using the (Mot. 1335) .

10A-163

15739-1

Place the valve insert (6) on the valve stem (the diameter of the valve insert should be identical to that of the valve stem).

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

15739-2

Keep the valve pressed against its seat. Mount the valve stem seal (not lubricated) over the valve insert. Push the valve stem seal until it goes past the valve insert. 15739-4

Fit the guide tube-pushrod assembly on the valve stem seal. Push home the valve stem seal by gently striking the pushrod with the palm of the hand, until the guide tube makes contact with the cylinder head. Repeat the preceding operations on all the inlet and exhaust valves.

15739-3

Remove the valve insert.

10A-164

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

16051-1

Refit:

16084

Refit the cotters using tweezers.

- the valve springs, positioning the conical part (7) of the spring at the top, - the valve spring upper cups (8) ,

20064

Refit the pushrods observing their original position. Oil the valve pushrods and the camshaft bearings with engine oil.

113566

Compress the valve springs using the (Mot. 1502) or a valve wrench.

10A-165

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

113565

113556

Refit:

Refit the camshaft.

- the camshaft pulley hub, - the camshaft pulley, - the old exhaust camshaft pulley mounting nut. Tighten to torque the mounting nut for the camshaft pulley (15 ± 1.5 Nm) , blocking the camshaft pulley with the (Mot. 799-01) . Check and adjust the valve clearances following the procedure below.

113562

Refit the camshaft bearing caps (observing their original positions, bearing No. 1 (10) engine flywheel end).

86911

Position the cylinder valves (1) in the end of exhaust stroke, beginning of inlet stroke position. Measure the valve clearance (X) of the cylinder (4) using a set of shims. - inlet valve clearance 0.20 mm , - exhaust valve clearance 0.40 mm , Note the clearance values. 20064-2

Repeat the above operations on the other cylinders:

Tighten to torque and in order the crankshaft bearing cap mounting bolts ( 11 ± 1.1 Nm ) .

- position cylinder No. 3 at an angle and measure the clearance of cylinder No. 2 ,

10A-166

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768 - position cylinder No. 4 at an angle and measure the clearance of cylinder No. 1 , - position cylinder No. 2 at an angle and measure the clearance of cylinder No. 3 , Compare the values noted with the specified values. Remove: - the nut from the camshaft pulley, - the camshaft pulley, - the camshaft pulley hub, - the camshaft bearing caps, - the camshaft, - the pushrod(s) which are outside of permitted tolerance values, noting their original position. Undertake the following installation to determine the class of thickness of the valve pushrod.

14678-1

Lift the top piece (17) of the dial gauge (without changing the position of the dial gauge-magnetic holder assembly). Mount the valve pushrod (18) to be measured on the plate of the (Mot. 252-01) . Take the measurement (Y) . Repeat the preceding operations for the other valve pushrods to be measured. Fit the new valve pushrod(s) in the cylinder head. Check that the camshaft pulley mounting stud has not come loose. If so, the stud must be replaced following the procedure described below. Place the camshaft in a vice fitted with a clamping jaw.

14678

Screw the extension piece (13) of the (Mot. 856-02) to a dial gauge (15) . Fix the dial gauge (15) to a magnetic holder (16) . Mount the dial gauge-magnetic holder assembly on the plate (14) of the tool (Mot. 252-01) . Calibrate the dial gauge.

10A-167

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

113565

Refit the camshaft.

109050

Remove the piston rings using a roller-type stud removal tool (19) . Clean the threaded hole of the camshaft carefully to prevent foreign bodies from entering the latter. Fit the new stud on the camshaft (precoated section (20) on the camshaft side). Tighten to torque the camshaft pulley mounting stud ( 12 ± 2 Nm ) using a roller-type stud removal tool (19) . 113562

Oil the top of the valve pushrods and the camshaft bearings with engine oil.

Refit the camshaft bearing caps (observing their original positions, bearing No. 1 (22) engine flywheel end).

20064-1

Degrease the surfaces of the camshaft bearing gaskets nos. 1 and 6 (21) using degreaser.

20064-2

Apply four beads of LOCTITE 518 of a width of 1 mm to camshaft bearings nos. 1 and 6 (21) .

Tighten to torque and in order the crankshaft bearing cap mounting bolts ( 11 ± 1.1 Nm ) .

10A-168

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768 Apply degreaser to: - the end of the camshaft at the timing end, - the housing on the cylinder head of the camshaft gasket.

21687-2

Position the cover (25) and collar nut (2 4) of the (Mot. 1632) . 21687

Screw the shouldered stud (23) of the (Mot. 1632) onto the mounting stud of the camshaft pulley.

21687-3

Screw on the collar nut until the cover touches the cylinder head. Remove: 21687-1

Refit the camshaft gasket.

- the collar nut, - the cap, - the collared stud. Using degreaser, degrease the surfaces of the exhaust manifold and cylinder head gaskets at the exhaust end.

10A-169

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768 Put a little engine oil from an oil can in the oil circuit of the turbocharger.

Refit: - a new exhaust manifold gasket, - the exhaust manifold, - the exhaust manifold mounting nuts.

113561

Tighten to torque and in order the exhaust manifold mounting nuts ( 26 ± 2.6 Nm ) . Using degreaser, degrease the surfaces of the exhaust manifold (where the turbocharger enters) and the turbocharger gaskets.

114285

Note: These two turbocharger oil supply pipes may be used on the same engine. The tightening torque of the end pieces (29) on the cylinder head is different, depending on the following: - if the end piece is shouldered (28) , in this case there will be no need to place the highresistance bolt locking product on the end piece thread, - if the end piece is not shouldered (27) , in this case it is essential to place the high-resistance bolt locking product on the end piece thread,

113560

Refit: - the new turbocharger seal, - the turbocharger. - the turbocharger mounting nuts. Tighten to torque the turbocharger mounting nuts ( 26 ± 2.6 Nm ) .

10A-170

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

113559

113558

Refit the turbocharger oil supply pipe (26) .

Refit:

Screw on:

- the EGR valve-exchanger assembly,

- the nut (30) on the cylinder head,

- the mounting bolts (32) (without tightening them) of the EGR valve-exchanger.

- the bolt (31) on the turbocharger. Tighten to torque:

Tighten to torque the EGR valve-exchanger mounting bolts ( 25 ± 2.5 Nm ) . (32)

- the turbocharger oil supply pipe mounting bolt (turbocharger end) ( 23 ± 2.3 Nm ) ,

Refit:

- the turbocharger oil supply pipe mounting nut (cylinder head end) ( collar nut 35 ± 3.5 Nm or no collar nut 23 ± 2.3 Nm ) .

- the new exhaust gas recirculation pipe (35) fitted with its new snap-on clip (34) , - the mounting bolts (33) of the exhaust gas recirculation pipe. Adjust the exhaust gas recirculation pipe in relation to the cooler support. Lock the snap-on clip of the exhaust gas recirculation pipe using the (Mot. 1567) . Tighten to torque the mounting bolts of the exhaust gas recirculation pipe ( 35 ± 3.5 Nm ) (33) . Fit the new O-ring seals to the inlet pipe.

10A-171

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768 Fit new seals to the cylinder head coolant outlet and the EGR exchanger cover.

113557

Refit: 113555

- the inlet duct,

Refit:

- the engine lifting eye (timing end),

- the cylinder head coolant outlet unit-EGR exchanger cover assembly,

- the engine lifting eye mounting bolts.

Tighten to torque the engine lifting eye mounting bolts (timing end) ( 21 ± 2.1 Nm ) .

- the cylinder head coolant outlet unit mounting bolts, - the EGR exchanger cover mounting bolts.

Refit:

Tighten to torque:

- the camshaft pulley hub,

- the cylinder head coolant outlet bolt ( 11 ± 1.1 Nm ) ,

- the new exhaust camshaft pulley hub mounting nut.

- the EGR exchanger cover mounting bolt ( 12 ± 1.2 Nm ) .

113738

Immobilise the hub using the (Mot. 799-01) .

113554

Tighten to torque and angle the camshaft pulley hub nut ( 30 ± 3 Nm + 86˚ ± 6˚ ) .

Refit:

Refit the camshaft pulley (without tightening the mounting bolts).

- the vacuum pump mounting bolts,

Using degreaser, degrease the surfaces of the seals where the vacuum pump enters, the cylinder head coolant outlet and the EGR exchanger cover.

10A-172

- the vacuum pump,

Tighten to torque the vacuum pump mounting bolts ( 21 ± 2.1 Nm ) . Refit the heater plugs.

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768 Tighten to torque the heater plugs ( 15 ± 1.5 Nm ) using a wrench with hinge.

20071

Refit: 19724

- the engine lifting eye (flywheel end), - the new heat protection washers,

Note: If one or more injectors are replaced, note the alphanumeric code (C2I) (34) and the number of the cylinder on which it is fitted.

- the injectors (observing their positions), - the injector brackets. Tighten to torque: - the engine lifting eye mounting bolts (flywheel end) ( 13 ± 1.3 Nm ) (32) , - the injector bracket bolts ( 28 ± 2.8 Nm ) (33) .

10A-173

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

20072

Refit:

20960

Lightly lubricate the nut threads with oil from the applicator supplied with the new part, taking care not to insert it in the pipe.

- the high-pressure pump, - the injector rail (without tightening the nuts) , Tighten to torque the high-pressure pump mounting bolts ( 21 ± 2.1 Nm ) .

Note: Do not lubricate high-pressure pipes supplied without an applicator; these pipes are selflubricating.

20073

Insert the high-pressure pipe olive in the injector high-pressure inlet taper. Insert the high-pressure pipe olive in the rail highpressure outlet taper. Finger tighten the high-pressure pipe nuts, starting with the one located on the injector end. Lightly tighten the nuts of the high-pressure pipes.

10A-174

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

19723

Fit the new clip provided with the new high-pressure pipe. Tighten to torque the injector rail mounting nuts ( 28 ± 2.8 Nm ) .

Note: Completely tighten one high-pressure pipe before moving to the next one. Tighten to torque and in order (according to the part no. of the pipe) the pump-rail high-pressure pipe nuts ( 24 ± 2.4 or 38 ± 3.8 Nm ) : - the high-pressure pump side, using the (Mot. 1746) or a crow foot wrench, - the injector rail side, using the (Mot. 1746) or a crow foot wrench, Tighten to torque and in order (according to the part no. of the pipe) the rail-injectors high-pressure pipe nuts ( 24 ± 2.4 or 38 ± 3.8 Nm ) : - the injector side using the (Mot. 1566) or with a wrench for high-pressure pipes. - the injector rail side, using the (Mot. 1566) or a crow foot wrench,

10A-175

10A

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 732 or 764 Tightening torquesm

Special tooling required Mot. 1511-01

Valve stem seal fitting tool adapter.

EGR valve-exchanger mounting bolts

25 ± 2.5 Nm

Mot. 1335

Pliers for removing valve stem seals.

mounting bolts of the exhaust gas recirculation pipe

35 ± 3.5 Nm

Mot. 1502

Valve lifting tool for removing valves.

engine lifting eye mounting bolts (timing end)

21 ± 2.1 Nm

camshaft pulley hub nut

30 ± 3 Nm + 86˚ ± 6˚

the cylinder head coolant outlet unit bolt

11 ± 1.1 Nm

the EGR exchanger cover mounting bolt

12 ± 1.2 Nm

vacuum pump mounting bolts

21 ± 2.1 Nm

the heater plugs

15 ± 1.5 Nm

Mot. 799-01

Timing gear wheel immobiliser.

Mot. 856-02

Dial gauge support.

Mot. 252-01

Dial gauge support thrust plate.

Mot. 1632

Tool for fitting PTFE camshaft seal

Mot. 1567

Long nose pliers for EGR duct clips.

Mot. 1566

Spanner for removing high pressure pipes.

Mot. 1746

Offset spanner for tightening high pressure pump pipes.

Tightening torquesm

the injector bracket mounting bolts

30 ± 3 Nm

injector rail mounting nuts

28 ± 2.8 Nm

the rail-injectors highpressure pipe nuts

24 ± 2.4 or 38 ± 3.8 Nm

the crankshaft bearing cap mounting bolts

11 ± 1.1 Nm

high-pressure pump mounting bolts

21 ± 2.1 Nm

the camshaft pulley mounting stud

12 ± 2 Nm

the rail-injectors highpressure pipe nuts

24 ± 2.4 or 38 ± 3.8 Nm

crankshaft bearing cap mounting bolts

11 ± 1.1 Nm

high-pressure protector bolts and nuts

21 ± 2.1 Nm

exhaust manifold mounting nuts

26 ± 2.6 Nm

turbocharger mounting nuts

26 ± 2.6 Nm

the turbocharger oil supply pipe mounting bolt (turbocharger end)

23 ± 2.3 Nm

the turbocharger oil supply pipe mounting nut (cylinder head end)

35 ± 3.5 Nm

I - RECOMMENDATIONS FOR REPAIR

IMPORTANT It is essential to follow the cleanliness guidelines (see Engine: Precautions during repair ). Wear latex gloves while using the cleaning product.

10A-176

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 732 or 764

WARNING Before fitting a new high-pressure pipe, lightly lubricate the nut threads with oil from the applicator provided with the new part. Be careful not to allow oil into the high-pressure pipe. Do not lubricate high-pressure pipes supplied without an applicator; these pipes are self-lubricating. Do not remove the blanking plugs from each component until the last moment. Do not blast with compressed air once the fuel circuit is open, otherwise impurities may enter the system. Tighten to torque ( 38 ± 3.8 Nm ) the pump-rail and rail-injectors high-pressure pipes, part nos.: - 77 01 207 025

20960

- 77 01 207 026 - 77 01 207 027 - 77 01 207 028 - 77 01 207 029 For the high-pressure pipes with the remaining part nos, tighten to a torque of ( 24 ± 2.4 Nm ). Applying excess sealant could cause it to be squeezed out when parts are tightened. A mixture of sealant and fluid could damage certain components (engine, radiator, etc.) The sealing surfaces must be clean, dry and free from grease (avoid finger marks). The gaskets must always be replaced. The camshaft pulley mounting stud must be replaced if it comes loose as the camshaft pulley is removed. Do not grease the valve stem seals.

II - PARTS AND CONSUMABLES FOR THE REPAIR Parts always to be replaced - Camshaft pulley nut, - Camshaft seal (timing end), - The injector heat protection washers, - high-pressure pipes, - The EGR exchanger cover seal, - The vacuum pump seal,

10A-177

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting K9K, and 732 or 764 - The cylinder head coolant outlet unit seal, - The exhaust manifold gasket, - The turbocharger seal - The inlet tube gasket, - The exhaust gas recirculation pipe, - The EGR solenoid valve seal, - Valve stem seals Consumables - Loctite 518, part no. 77 01 421 162 , - High-resistance bolt locking product, part no. 77 11 230 112 , - Degreasing agent, part no. 77 11 224 559 .

III - EQUIPMENT REQUIRED

- Latex protective gloves, - Valve wrench, - Tweezers, - Wrench for the high-pressure pipes, - Crow foot wrench, - Wrench with hinge for heater plugs, - Roller-type stud removal tool - Oil can, - The valve stem seal fitting kit, - Dial gauge, - Magnetic holder, - Torque/angle wrench, - Torque wrench - Cylinder head bolt tightening gauge (angular measuring type).

IV - REASSEMBLING THE CYLINDER HEAD

10A-178

10A

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 732 or 764

15738

18077

Note: Before removing the valve stem seals, it is essential to note the position (H) of the former seals on the inlet side, then the exhaust side as the fitting dimension of the seals may be different between the inlet and the exhaust. Fit a valve. Compare the dimension (H) of an old seal with the cylinder head using the (Mot. 1511-01) (4) or the valve stem seal fitting set (5) . 19675

Note: The internal diameter of the pushrod (1) should be identical to that of the valve; In addition, the bottom of the pushrod must be snug against the metal upper section of the valve stem seal.

10A-179

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 732 or 764 Apply engine oil to the inside of the valve guide.

15738-1 15739

Place the pushrod (1) over the valve stem seal. Place the valve in the cylinder head.

17999

Fit the guide tube (2) above the pushrod until it comes into contact with the cylinder head. Lock the pushrod with the wheel (3) . Remove the guide tube-pushrod assembly, being careful not to loosen the wheel. Remove: - the valve, - the valve stem seals (inlet end then exhaust end) using the (Mot. 1335) .

10A-180

15739-1

Place the valve insert (6) on the valve stem (the diameter of the valve insert should be identical to that of the valve stem).

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 732 or 764

15739-2

Keep the valve pressed against its seat. Mount the valve stem seal (not lubricated) over the valve insert. Push the valve stem seal until it goes past the valve insert. 15739-4

Fit the guide tube-pushrod assembly on the valve stem seal. Push home the valve stem seal by gently striking the pushrod with the palm of the hand, until the guide tube makes contact with the cylinder head. Repeat the preceding operations on all the inlet and exhaust valves.

15739-3

Remove the valve insert.

10A-181

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 732 or 764

16051-1

Refit:

113567

Refit the cotters using tweezers.

- the valve springs, positioning the conical part (7) of the spring at the top, - the valve spring upper cups (8) .

113564

Refit the pushrods observing their original position. Lubricate the valve pushrods and the camshaft bearings with engine oil.

113566

Compress the valve springs using the (Mot. 1502) or a valve wrench.

10A-182

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 732 or 764

113565

113556

Refit:

Refit the camshaft.

- the camshaft pulley hub, - the camshaft pulley, - the old camshaft pulley mounting nut. Tighten to torque the mounting nut for the camshaft pulley (15 ± 1.5 Nm) , blocking the camshaft pulley with the (Mot. 799-01) . Check and adjust the valve clearance following the procedure below.

113562

Refit the camshaft bearing caps (observing their original positions, bearing No. 1 (10) engine flywheel end).

86911

Position the cylinder valves (1) in the end of exhaust stroke, beginning of inlet stroke position. Measure the valve clearance (X) of the cylinder (4) using a set of shims: - inlet valve clearance 0.20 mm , - exhaust valve clearance 0.40 mm , Note the clearance values. 113563

Repeat the above operations on the other cylinders:

Tighten to torque and in order the crankshaft bearing cap mounting bolts ( 11 ± 1.1 Nm ) .

- position cylinder No. 3 at an angle and measure the clearance of cylinder No. 2 ,

10A-183

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 732 or 764 - position cylinder No. 4 at an angle and measure the clearance of cylinder No. 1 , - position cylinder No. 2 at an angle and measure the clearance of cylinder No. 3 , Compare the values noted with the specified values. Remove: - the nut from the camshaft pulley, - the camshaft pulley, - the camshaft pulley hub, - the camshaft bearing caps, - the camshaft, - the pushrod(s) which are outside of permitted tolerance values, noting their original position. Undertake the following installation to determine the class of thickness of the valve pushrod.

14678-1

Lift the top piece (17) of the dial gauge (without changing the position of the dial gauge-magnetic holder assembly). Mount the valve pushrod (18) to be measured on the plate of the (Mot. 252-01) . Take the measurement (Y) . Repeat the preceding operations for the other valve pushrods to be measured. Fit the new valve pushrod(s) in the cylinder head. Check that the camshaft pulley mounting stud has not come loose. If so, the stud must be replaced following the procedure described below. Place the camshaft in a vice fitted with a clamping jaw.

14678

Screw the extension piece (13) of the (Mot. 856-02) to a dial gauge (15) . Fix the dial gauge (15) to a magnetic holder (16) . Mount the dial gauge-magnetic holder assembly on the plate (14) of the (Mot. 252-01) . Calibrate the dial gauge.

10A-184

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 732 or 764

113565

Refit the camshaft.

109050

Remove the piston rings using a roller-type stud removal tool (19) . Clean the threaded hole of the camshaft carefully to prevent foreign bodies from entering the latter. Fit the new stud on the camshaft (precoated section (20) on the camshaft side). Tighten to torque the camshaft pulley mounting stud ( 12 ± 2 Nm ) using a roller-type stud removal tool (19) . 113562

Oil the top of the valve pushrods and the camshaft bearings with engine oil.

Refit the camshaft bearing caps (observing their original positions, bearing No. 1 (22) engine flywheel end).

20064-1

Degrease the surfaces of the camshaft bearing gaskets nos. 1 and 6 (21) using degreaser.

113563

Apply four beads of LOCTITE 518 of a width of 1 mm to camshaft bearings nos. 1 and 6 (21) .

Tighten to torque and in order the crankshaft bearing cap mounting bolts ( 11 ± 1.1 Nm ) .

10A-185

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 732 or 764 Apply degreaser to: - the end of the camshaft at the timing end, - the housing on the cylinder head of the camshaft gasket.

21687-2

Position the cover (25) and collar nut (24) of the tool (Mot. 1632) . 21687

Screw the shoulder stud (23) of the (Mot. 1632) onto the mounting stud of the camshaft pulley.

21687-3

Screw on the collar nut until the cover touches the cylinder head. Remove: 21687-1

Refit the camshaft gasket.

- the collar nut, - the cap, - the shoulder stud. Using degreaser, degrease the surfaces of the exhaust manifold and cylinder head gaskets at the exhaust end.

10A-186

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 732 or 764 Put a little engine oil from an oil can in the oil circuit of the turbocharger.

Refit: - a new turbocharger-exhaust manifold gasket, - the exhaust manifold, - the exhaust manifold mounting nuts.

113559

Refit the turbocharger oil supply pipe (26) . Screw: 113561

Tighten to torque and in order the exhaust manifold mounting nuts ( 26 ± 2.6 Nm ) . Using degreaser, degrease the surfaces of the exhaust manifold (where the turbocharger enters) and the turbocharger gaskets.

- the cylinder head nut (30) , - the bolt (31) on the turbocharger. Tighten to torque: - the turbocharger oil supply pipe mounting bolt (turbocharger end) ( 23 ± 2.3 Nm ) , - the turbocharger oil supply pipe mounting nut (cylinder head end) ( 35 ± 3.5 Nm ) .

113560

Refit: - the new turbocharger gaskets, - the turbocharger. - the turbocharger mounting nuts Tighten to torque the turbocharger mounting nuts ( 26 ± 2.6 Nm ) .

10A-187

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 732 or 764

113558

113557

Refit:

Refit:

- the EGR valve-exchanger assembly,

- the inlet duct,

- the mounting bolts (32) (without tightening them) of the EGR valve-exchanger.

- the engine lifting eye (timing end),

Tighten to torque the EGR valve-exchanger mounting bolts ( 25 ± 2.5 Nm ) . (32) Refit: - the new exhaust gas recirculation pipe (35) fitted with its new snap-on clip (34) , - the mounting bolts (33) of the exhaust gas recirculation pipe. Adjust the exhaust gas recirculation pipe in relation to the cooler support.

- the engine lifting eye mounting bolts.

Tighten to torque the engine lifting eye mounting bolts (timing end) ( 21 ± 2.1 Nm ) . Refit: - the camshaft pulley hub, - the new camshaft pulley hub mounting nut.

Lock the snap-on clip of the exhaust gas recirculation pipe using the (Mot. 1567) . Tighten to torque the mounting bolts of the exhaust gas recirculation pipe ( 35 ± 3.5 Nm ) (33) . Fit the new O-ring seals to the inlet pipe.

113738

Immobilise the hub using the (Mot. 799-01) . Tighten to torque and angle the camshaft pulley hub nut ( 30 ± 3 Nm + 86˚ ± 6˚ ) . Refit the camshaft pulley (without tightening the mounting bolts). Using degreaser, degrease the surfaces of the seals where the vacuum pump enters, the cylinder head coolant outlet and the EGR exchanger cover.

10A-188

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 732 or 764 Refit new seals to the cylinder head coolant outlet and the EGR exchanger cover.

Tighten to torque the heater plugs ( 15 ± 1.5 Nm ) using a hinged wrench.

113555

113597

Refit:

Refit:

- the cylinder head coolant outlet unit-EGR exchanger cover assembly,

- engine lifting eye (flywheel end) (36) ,

- the cylinder head coolant outlet unit mounting bolts, - the EGR exchanger cover mounting bolts.

- the injector rail (without tightening the nuts) , - the new heat protection washers, - the injectors (observing their positions), - the injector bracket spacer,

Tighten to torque:

- the injector brackets,

- the cylinder head coolant outlet unit bolt ( 11 ± 1.1 Nm ) ,

- the injector bracket mounting bolts (38) .

- the EGR exchanger cover mounting bolt ( 12 ± 1.2 Nm ) .

Tighten to torque the injector bracket mounting bolts ( 30 ± 3 Nm ) .

Note: Do not lubricate high-pressure pipes supplied without an applicator; these pipes are selflubricating.

113554

Refit: - the vacuum pump, - vacuum pump mounting bolts, Tighten to torque the vacuum pump mounting bolts ( 21 ± 2.1 Nm ) . Refit the heater plugs.

10A-189

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 732 or 764

113601

Refit: - the high-pressure pump, - the mounting bolts of the high-pressure pump 20960

Lightly lubricate the nut threads with oil from the applicator supplied with the new part, taking care not to insert it in the pipe. Insert the high-pressure pipe olive in the injector high-pressure inlet taper. Insert the high-pressure pipe olive in the rail highpressure outlet taper.

Tighten to torque the high-pressure pump mounting bolts ( 21 ± 2.1 Nm ) .

Note: Do not lubricate high-pressure pipes supplied without an applicator; these pipes are selflubricating.

Finger tighten the high-pressure pipe nuts, starting with the one located on the injector end. Lightly tighten the nuts of the high-pressure pipes. Tighten to torque the injector rail mounting nuts ( 28 ± 2.8 Nm ) .

Note: Completely tighten one high-pressure pipe before moving to the next one. Tighten to torque and in order (according to the part no. of the pipe) the rail-injectors high-pressure pipe nuts ( 24 ± 2.4 or 38 ± 3.8 Nm ) : - injector rail side, using the (Mot. 1566) or a crow foot wrench, - injector side using the (Mot. 1566) or with a wrench for high-pressure pipes. 20960

Lightly lubricate the nut threads with oil from the applicator supplied with the new part, taking care not to insert it in the pipe. Position the high-pressure pipe olive in the highpressure spherical injector rail inlet.

10A-190

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder head: Refitting

10A

K9K, and 732 or 764 Insert the high-pressure pipe olive in the high-pressure pump high-pressure outlet taper.

Refit the fuel return pipe.

Finger tighten the high-pressure pipe nuts, starting with the one at the injector rail side. Lightly tighten the nuts of the high-pressure pipes.

113595

Refit: - the high-pressure protector, - the mounting bolt and nuts of the high-pressure protector, Tighten to torque the high-pressure protector bolts and nuts ( 21 ± 2.1 Nm ) .

113593

113594

Tighten to torque and in order (according to the part no. of the pipe) the rail-injectors high-pressure pipe nuts ( 24 ± 2.4 or 38 ± 3.8 Nm ) : - the injector rail side using the (Mot. 1566) (39) , - the high-pressure pump side using the (Mot. 1746) (40) .

10A-191

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Dismantling

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 722 or 750 or 752 or 790 Remove:

Special tooling required

- the clutch mechanism mounting bolts, Mot. 582-01

Flywheel locking tool.

Mot. 1677

Flywheel locking tool.

Emb. 1596

2 4 mm socket for removing/refitting clutch master cylinder.

Mot. 1329

Oil filter removing tool (76 mm diameter).

- the clutch pressure plate, - the clutch plate.

I - RECOMMENDATIONS FOR REPAIR

IMPORTANT Wear protective gloves during every operation.

II - EQUIPMENT REQUIRED

- Wide, flat-blade screwdriver, 20172

- Male torx socket. Remove: - the flywheel mounting bolts,

III - STRIPPING THE CYLINDER BLOCK

- the (Mot. 582-01) or (Mot. 1677) , 1 - For engines fixed to the oil filter side

- the flywheel.

19652

Fit the engine flywheel lock (Mot. 582-01) or (Mot. 1677) .

10A-192

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Dismantling

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 722 or 750 or 752 or 790 - the power assisted steering pump or the dummy pulley.

2 - For engines fixed to the flywheel side

107853 19704

111079

111057

Remove:

Remove:

- the alternator mounting bolts (1) ,

- the multifunction support mounting bolts,

- the alternator using a wide, flat-blade screwdriver (if necessary),

- the multifunction support.

- the mounting bolts (2) of the air conditioning compressor (if fitted), - the air conditioning compressor, - the mounting bolts (3) of the power assisted steering pump or the dummy pulley (if fitted),

10A-193

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Dismantling

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 722 or 750 or 752 or 790 - the oil pressure sensor (7) , - the oil filter using the (Mot. 1329) , - the oil filter holder mounting bolt (8) ,

19706

Unclip the hose connections (5) of the coolant pump inlet pipe. Remove:

20156

- the mounting bolt (4) of the coolant pump inlet pipe,

Remove:

- the coolant pump inlet pipe.

- the oil/coolant heat exchanger mounting bolt, - the oil/coolant heat exchanger.

3 - For engines fixed to the oil filter side or the flywheel side

20171 20157

Remove:

Remove:

- the oil sump mounting bolts.

- the acceleration meter (6) using tool (Emb. 1596) ,

- the engine oil sump.

10A-194

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Dismantling

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 722 or 750 or 752 or 790

20169

20168

Remove:

Remove the oil splash plate.

- the oil level sensor (11) , - the oil pump mounting bolts (12) , - the oil pump.

20165

Remove: - the coolant pump mounting bolts (9) , - the coolant pump,

20164

- the crankshaft nose closure panel mounting bolt (10) , - the crankshaft nose closure panel

Remove: - the oil pump chain, - the oil pump drive sprocket.

10A-195

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Dismantling

10A

K9K, and 274 or 276 or 712 or 714 or 716 or 718 or 724 or 728 or 729 or 760 or 762 or 766 or 768 Special tooling required Mot. 1677

Flywheel locking tool.

Mot. 1329

Oil filter removing tool (76 mm diameter).

Emb. 1596

2 4 mm socket for removing/refitting clutch master cylinder.

I - RECOMMENDATIONS FOR REPAIR

IMPORTANT Wear protective gloves during every operation.

II - EQUIPMENT REQUIRED 20172

Remove:

- Wide, flat-blade screwdriver,

- the flywheel mounting bolts,

- Male torx socket.

- (Mot. 1677) , - the flywheel.

III - STRIPPING THE CYLINDER BLOCK

19652

Fit the engine flywheel lock (Mot. 1677) . Remove: - the clutch mechanism mounting bolts, - the clutch pressure plate, - the clutch plate.

10A-196

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Dismantling

10A

K9K, and 274 or 276 or 712 or 714 or 716 or 718 or 724 or 728 or 729 or 760 or 762 or 766 or 768

107853

107855

Remove: - the multifunction support mounting bolts, - the multifunction support.

111079

Remove: - the alternator mounting bolts (12) , - the alternator using a wide flat-blade screwdriver (if necessary), - the mounting bolts (13) of the air conditioning compressor (if fitted),

107856

Remove: - the oil filter (1) using the (Mot. 1329) , - the oil filter holder mounting bolt (2) ,

- the air conditioning compressor, - the mounting bolts (14) of the power assisted steering pump or the dummy pulley if fitted, - the power assisted steering pump or the dummy pulley.

10A-197

- the oil filter holder.

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Dismantling

10A

K9K, and 274 or 276 or 712 or 714 or 716 or 718 or 724 or 728 or 729 or 760 or 762 or 766 or 768

107857

20171

Remove:

Remove:

- the mounting bolt (3) from the oil/coolant heat exchanger,

- the engine oil sump mounting bolts,

- the oil/coolant heat exchanger (4) .

- the engine oil sump.

K9K, and 712 or 728

107858

Remove: - the acceleration meter (5) using the (Emb. 1596) , - the oil level sensor (6) ,

20169

Remove the oil splash plate.

- the mounting bolt (7) of the coolant pump inlet pipe, - the coolant pump inlet pipe (8) .

10A-198

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Dismantling

10A

K9K, and 274 or 276 or 712 or 714 or 716 or 718 or 724 or 728 or 729 or 760 or 762 or 766 or 768

20165

20164

Remove:

Remove:

- the coolant pump mounting bolts (9) ,

- the oil pump chain,

- the coolant pump,

- the oil pump drive sprocket.

- the crankshaft nose closure panel mounting bolt (10) , - the crankshaft nose closure panel

113577

Remove: - the oil pump mounting bolts (11) , - the oil pump.

10A-199

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Dismantling

10A

K9K, and 732 or 764 Special tooling required Mot. 1329

Oil filter removing tool (76 mm diameter).

Mot. 1677

Flywheel locking tool.

I - RECOMMENDATIONS FOR REPAIR

IMPORTANT Wear protective gloves during every operation.

II - EQUIPMENT REQUIRED

- Wide, flat-blade screwdriver, - Male torx socket. 113486

Remove:

III - STRIPPING THE CYLINDER BLOCK

- the air conditioning compressor mounting bolts, - the air conditioning compressor.

113487

Remove: - the alternator mounting bolts (1) ,

113485

- the alternator using a wide flat-blade screwdriver (if necessary),

Remove: - the multifunction support mounting bolts, - the multifunction support (3) .

10A-200

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Dismantling

10A

K9K, and 732 or 764

113484

Remove the oil filter using the (Mot. 1329) .

113482

Remove: - the mounting bolt (6) from the oil/coolant heat exchanger, - the oil/coolant heat exchanger (7) .

113483

Remove: - the oil filter holder mounting bolt (4) , - the oil filter holder (5) . 113481

Remove: - the oil level sensor (8) , - the mounting bolt (9) of the coolant pump inlet pipe, - the coolant pump inlet pipe (10) .

10A-201

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Dismantling

10A

K9K, and 732 or 764

113491

113492

Fit the engine flywheel lock (Mot. 1677) (11) .

Remove:

Remove:

- the engine oil sump mounting bolts,

- the mounting bolts (12) of the clutch pressure plate, using a male torx socket,

- the engine oil sump.

- the clutch pressure plate, - the friction plate.

113488

Remove:

113571

- the mounting bolts of the flywheel, using a male torx socket,

Remove: - the coolant pump mounting bolts,

- the flywheel block (Mot. 1677) ,

- the coolant pump.

- the flywheel.

10A-202

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Dismantling K9K, and 732 or 764

113570

Remove: - the crankshaft nose closure panel mounting bolt, - the crankshaft nose closure panel.

113577

Remove: - the oil pump mounting bolts (13) , - the oil pump (15) , - the oil pump chain (14) , - the oil pump drive sprocket (16) .

10A-203

10A

ENGINE AND LOWER ENGINE ASSEMBLY Running gear:Removal I - RECOMMENDATIONS FOR REPAIR

10A

III - REMOVING THE ROTATING PARTS

IMPORTANT Wear protective gloves during every operation.

WARNING Do not use a punch or an etching tool to mark the con rod caps to match their bodies, to prevent incipient breakage of the con rod. Use an indelible marker pen.

113575

Note:

Mark the con rod caps in relation to their bodies using an indelible pencil.

It is essential to mark: - the position of the crankshaft bearings as the class may be different for each bearing, - the height class of the pistons in relation to the cylinders, - the gudgeon pin in relation to the piston. II - EQUIPMENT REQUIRED

- Indelible pencil, - Female torx socket. - Mallet, - Roll pin punch ( 10 mm in diameter).

113576

Mark the crankshaft bearing caps (bearing No. 1 at the flywheel end) with an indelible pencil.

- Male Allen key ( 10 mm ), - Piston ring compressor, - Flat-blade screwdriver,

113574

Remove: - the con rod cap mounting bolts. - the con rod caps,

10A-204

ENGINE AND LOWER ENGINE ASSEMBLY Running gear:Removal

10A

- the con rod-piston assemblies.

113573

Remove: - the crankshaft bearing cap mounting bolts. - the crankshaft bearing caps.

113587

113572

Remove the crankshaft. Remove the thrust washer from the crankshaft.

113586

Remove the dipstick guide tube (if the cylinder block is fitted with one) using a 10mm (1) Allen key or a 10mm (2) pin punch.

10A-205

ENGINE AND LOWER ENGINE ASSEMBLY Running gear:Removal

113580

Remove the piston rings using a piston ring compressor.

113582

Remove the circlip using a flat-blade screwdriver. Mark the gudgeon pins in relation to the pistons using an indelible pencil. Remove the gudgeon pin.

10A-206

10A

ENGINE AND LOWER ENGINE ASSEMBLY Piston base cooling jet: Removal

10A

III - REMOVING THE PISTON BASE COOLING JETS

Special tooling required Mot. 1485-01

Tool for removing piston coolers.

Emb. 880

Pin extractor.

I - RECOMMENDATIONS FOR REPAIR

IMPORTANT Wear: - goggles, - protective gloves during the whole operation.

WARNING Do not withdraw the ball of the piston base cooling nozzle, to prevent swarf falling into the oil circuit.

14507

Drill the piston base cooling jets (1) using a 7 mm diameter drill bit.

II - EQUIPMENT REQUIRED

- Drill bit 7 mm in diameter - Allen key ( 6 mm ), - Brush,

2

- Protective goggles,

3

- Compressed air gun.

4

14803

Note: Do not remove the ball (4) . Remove: - the spring stop (2) , - the spring (3) . Wear protective goggles.

10A-207

ENGINE AND LOWER ENGINE ASSEMBLY Piston base cooling jet: Removal

10A

15259

15261

Move any swarf using a brush and compressed air gun.

Screw the large slide hammer (Emb. 880) on the (Mot. 1485-01) . Remove the piston base cooling jets.

15260-2

Screw the (Mot. 1485-01) into the drilled jet with a 6 mm Allen key, which should slide into the tool.

10A-208

ENGINE AND LOWER ENGINE ASSEMBLY Lower engine: Cleaning

IV - CLEANING THE CYLINDER BLOCK

Special tooling required Mot. 923

10A

Apply the DÉCAPJOINT product to the sections to be cleaned.

Engine lifting ring.

Leave for around ten minutes. I - RECOMMENDATIONS FOR REPAIR

Remove residues with a wooden spatula. Finish cleaning the parts using a grey polishing pad.

IMPORTANT Do not scratch the aluminium sealing surfaces. Wear goggles. Wear gloves during the operation.

WARNING Do not allow this product to drip on to the paintwork. Clean the cylinder block components carefully to prevent foreign bodies from entering the oil supply and return galleries. Failure to follow this advice could lead to the blocking of the various oil inlet galleries, which would quickly result in engine damage. When cleaning parts, it is essential to not knock the parts against each other, or their mating faces may be damaged and therefore their adjustments may be altered, which could damage the engine.

II - PARTS AND CONSUMABLES FOR THE REPAIR Consumables - Décapjoint, part no. 77 01 405 952 , - Grey sanding pad, part no. 77 01 405 943 . III - EQUIPMENT REQUIRED

- Protective goggles, - Protective gloves, - Wooden spatula, - Compressed air gun, - Load positioner, - Workshop hoist, - Cleaning fountain, - Cleaning bench.

10A-209

113585

Position the (Mot. 923) on the cylinder block. Remove the cylinder block from the engine stand using a load positioner and a workshop hoist.

ENGINE AND LOWER ENGINE ASSEMBLY Lower engine: Cleaning

113592

113553

Wash the cylinder block parts using a cleaning fountain or a heated cleaning bath.

10A-210

10A

ENGINE AND LOWER ENGINE ASSEMBLY Lower engine: Check

10A

IV - CYLINDER BLOCK CHECK

Special tooling required Mot. 1493-01

Crankshaft bearing centring tool.

Mot. 1492-03

Tool for fit ting main bearing shells.

Mot. 1492

Tool for fit ting main bearing shells.

1 - Checking the cylinder block gasket face

I - RECOMMENDATIONS FOR REPAIR

WARNING Parts should be clean before examining and testing them. 102786

No adjustment is authorised to the cylinder block or the crankshaft.

Use a cylinder head adjuster and set of shims to check the seal face bow. Maximum deformation: 0.03 mm .

II - PARTS AND CONSUMABLES FOR THE REPAIR Consumables

2 - Checking the diameter of the crankshaft bearings on the cylinder block

- Degreasing agent, part no. 77 11 224 559 .

Refit the crankshaft bearing caps, fitting cap no. 1 at the flywheel end.

III - EQUIPMENT REQUIRED

- Torque wrench and cylinder head bolt tightening gauge (angular measuring type), - Torque/angle wrench, - Radial play measuring tape. - Sliding calliper, - Micrometer, - Dial gauge, - Body jig bench and a pair of v-blocks. - Magnetic holder, - Set of shims, - Cylinder head rule.

10A-211

Torque and angle tighten the main bearing cap mounting bolts (25 ± 2.5 Nm + 47°° ± 6) .

ENGINE AND LOWER ENGINE ASSEMBLY Lower engine: Check

10A

- the diameter of the crankshaft bearings on the cylinder block is 51.936 to 51.942 mm excl. . (2) = 43 mm : - the diameter category is 2 , - the diameter of the crankshaft bearings on the cylinder block is 51.942 incl. to 51.949 mm . Remove the crankshaft bearing caps. 3 - Check the diameter of the crankshaft journals

10021

102805

Measure the diameter of the journals using a micrometer (X2) .

21697

Note: The hole (1) defines the diameter category of the crankshaft bearings on the cylinder block. It is only possible to have one diameter category of crankshaft bearings on one engine. Measure the dimension (2) to identify the diameter category of the crankshaft bearings on the cylinder block. (2) = 33 mm : - the diameter category is 1 ,

10A-212

ENGINE AND LOWER ENGINE ASSEMBLY Lower engine: Check Marking one

10A

Detail of marking "A".

107878

(1)

diameter category of journal no.1, flywheel end,

(2)

diameter category of journal no.5, timing end,

(3)

line indicating the diameter class of the journals,

(4)

line indicating the diameter class of the crankpins.

14512-1

Marking two

The marks of journal category A, G, K, R,W correspond to a diameter of 47.990 to 47.997 mm excl. , The marks of journal category B, H, L, S, Y correspond to a diameter of 47.997 incl. to 48.003 mm excl. , The marks of journal category C, J, O, T, Z correspond to a diameter of 48.003 incl. to 48.010 mm excl. , 4 - Check the diameter of the crankshaft crankpins

103689

102806

Using a micrometer, measure the diameter of the crankpins (X3) which should be 43.97 ± 0.01 mm .

10A-213

ENGINE AND LOWER ENGINE ASSEMBLY Lower engine: Check

10A

5 - Check for deformation of the contact surface of the crankshaft flywheel Position the crankshaft on the v-blocks Place the dial gauge at the base of the crankshaft. Measure the deformation of the contact surface of the flywheel which should not be greater than 0.6 mm . 6 - Checking the crankshaft lateral clearance

16359

Mount the grooved bearing shell on the (Mot. 149301) . Press at (11) on the bearing until it is in contact with the tool at (12) .

16359-1

Position the (Mot. 1493-01) on the cylinder block.

16358

Position the (Mot. 1493-01) on the crankshaft bearing cap.

10A-214

ENGINE AND LOWER ENGINE ASSEMBLY Lower engine: Check

10A

- the crankshaft thrust washer on bearing No.3 , positioning the grooves of the thrust washers at the crankshaft end. Refit the crankshaft bearing caps (positioning bearing cap No. 1 at the flywheel end).

16357

Fit the non grooved bearing shell into the (Mot. 1493-01) . Press at (13) on the bearing until it is in contact with the tool at (14) . Lubricate: - the crankshaft bearing shells (only the surface in contact with the crankshaft). - the crankshaft journals.

103281

Refit: - the crankshaft,

10A-215

20160

Torque and angle tighten in order the crankshaft bearing cap mounting bolts (25 ± 2.5 Nm + 47°° ± 6°°) . Check that the crankshaft turns freely, with no resistance.

ENGINE AND LOWER ENGINE ASSEMBLY Lower engine: Check

10A

20162

Check the lateral clearance of the crankshaft, which must be: - without thrust washer wear: 0.045 to 0.252 mm ,

103281

Refit: - the crankshaft, - the crankshaft thrust washer on bearing No.3 (grooves at crankshaft end).

- with thrust washer wear: 0.045 to 0.852 mm . Remove: - the crankshaft bearing caps, - the crankshaft. 7 - Checking the crankshaft diametric clearance

Note: Never turn the crankshaft during the operation. Remove any oil that may be on the crankshaft journals and cylinder block bearings.

102807

Cut bits of wire (2) to measure the clearance. Insert the wire into the axis of the crankshaft journals (avoiding the bearing lubrication holes).

10A-216

ENGINE AND LOWER ENGINE ASSEMBLY Lower engine: Check

10A

9 - Checking the centre distance of the con rod

102797

Using a micrometer, measure the diameter of the big end, which should be 47.619 ± 0.009 mm . 20160

10 - Checking the diameter of the con rod small end

Refit the crankshaft bearing caps, fitting No.1 at the flywheel end.

Using a micrometer, measure the diameter of the con rod small end (with ring):

Torque and angle tighten in order the crankshaft bearing cap mounting bolts (25 ± 2.5 Nm + 47°° ± 6°°) .

- For engines K9K 260-700-702-704-710-722 manufactured up to 25/11/2002 the diameter should be 25.019 ± 0.006 mm ,

Remove:

- For engines K9K 260-700-702-704-710-722 from 25/11/2002 and engines K9K 270-272-274-276706-712-714-716-718-724-728-729-732-750-752760-762-764-766-768-790-792, the diameter should be between 26.019 ± 0.006 mm .

- the crankshaft bearing caps, - the crankshaft. Measure the flattening of the clearance measuring wire using packaging paper (3) . Check the clearance value, which must be between 0.010 and 0.054 mm .

11 - Checking the diametric clearance of the big ends

Clean any traces of measuring wire off the crankshaft and the bearing shells using degreasing agent.

Note: Never turn the crankshaft during the operation.

8 - Checking the centre distance of the con rod The distance between the small end and big end of the con rod should be 133.75 mm .

10A-217

Remove any oil that may be on the crankshaft journals and cylinder block bearings.

ENGINE AND LOWER ENGINE ASSEMBLY Lower engine: Check

103281

Refit: - the crankshaft, - the crankshaft thrust washers on bearing No.3 (grooves at crankshaft end).

10A

21688

Slide the bearing support (22) (positioning the marking "A" (23) as indicated in the diagram) of the (Mot. 1492-03) in the groove (24) of the tool block (Mot. 1492) .

21689 20160

Refit the crankshaft bearing caps, fitting No.1 at the flywheel end. Torque and angle tighten in order the crankshaft bearing cap mounting bolts (25 ± 2.5 Nm + 47°° ± 6°°) . Refitting the con rod bearings on the con rod body.

10A-218

Place the rail (25) of the (Mot. 1492-03) on the base.

ENGINE AND LOWER ENGINE ASSEMBLY Lower engine: Check

21690

Mount the con rod body on the base. Check that the lower part (26) of the small end is in contact with the centring pin. Push the rail (in the direction shown by the arrow) until the rail presses against the con rod end.

21691

Mount the bearing shell (27) (with a width of 20.625 mm on the bearing shell support. Push the bearing shell support in the direction shown by the arrow.

10A-219

10A

21692

Bring the bearing shell support to the end of the con rod body base. Remove the support shell from the con rod body. Repeat the operation for the other con rod bodies. Refitting the con rod bearings on the con rod cap.

ENGINE AND LOWER ENGINE ASSEMBLY Lower engine: Check

10A

21693

Position the bearing shell support, aligning the marking "A" or "B" (28) on the side of the cap as follows: - a bearing shell width of 20.625 mm corresponds to "A",

21695

Mount the bearing shell (30) on the bearing shell support. Push the bearing shell support in the direction shown by the arrow.

- a bearing shell width of 17.625 mm corresponds to "B", Mount the con rod cap on the base.

21696

Bring the bearing shell support to the end of the con rod cap base. Remove the bearing shell from the con rod cap. 21694

Push the rail in the direction shown by the arrow until the con rod cap presses against the pins (29) on the base.

10A-220

Repeat the operation for the other con rod caps. Using an indelible pencil, mark the gudgeon pin position in relation to the piston. Lubricate gudgeon pin with engine oil.

ENGINE AND LOWER ENGINE ASSEMBLY Lower engine: Check

10A

Check that the gudgeon pin slides and turns freely in the piston.

16242 113583

Position the mark "V" (31) of the piston and the flat surface (32) of the con rod cap as indicated in the illustration.

Using degreasing agent, degrease the contact surfaces (35) between the cap and body of the con rod.

Note: Ensure that the piston matches the cylinder block barrel (No.1 at flywheel end) . Ensure the correct con rod-piston orientation, positioning the "V" engraved on the piston crown towards the flywheel . Refit the con rod-piston assembly (without piston rings) onto the cylinder block. Mount the con rod heads on the crankshaft crankpins.

21700

Refit the circlip of the gudgeon pin, positioning the opening (34) of the circlip opposite the notch (33) .

10A-221

ENGINE AND LOWER ENGINE ASSEMBLY Lower engine: Check

10A

Clean any traces of measuring wire off the crankshaft and the bearing shells using degreasing agent. Remove: - the crankshaft bearing caps, - the con rod pistons, - the crankshaft. 12 - Checking the thickness of the piston rings Measure the thickness of the piston rings using a micrometer. - the compression ring must be 2 mm -0.01 / -0.03 . - the sealing ring must be 2 mm -0.01 / -0.03 . - the scraper ring must be 2.5 mm -0.01 / -0.03 . 102807

Cut bits of wire (2) used to measure the clearance. Insert the wire into the axis of the crankshaft crankpins (avoiding the bearing lubrication holes).

13 - Checking the clearance between the piston grooves and the piston rings

102795 113574

Refit: - the con rod caps, ensuring correct matching,

Measure the clearance between the piston grooves and piston rings using a set of shims (4) . - (A) : Set of shims incorrectly positioned,

- the con rod cap mounting bolts. Torque and angle tighten the con rod cap mounting bolts (20 ± 2 Nm + 45°° ± 6) . Remove:

- (B) : Set of shims correctly positioned. The compression ring clearance must be 0.10 to 0.12 mm . The clearance for the sealing ring must be 0.08 to 0.10 mm .

- the con rod caps, - the con rod-piston assembly. Measure the flattening of the clearance measuring wire using packaging paper (3) .

the scraper ring clearance must be 0.03 to 0.05 mm .

Check the clearance value, which must be between 0.010 and 0.064 mm .

If the clearance is not within tolerance, replace the piston-gudgeon pin assembly, or the piston rings.

10A-222

ENGINE AND LOWER ENGINE ASSEMBLY Lower engine: Check

10A

- 75.945 ± 0.007 mm for engines K9K 276-712-718724-728-729-732-760-764-766.

14 - Checking clearance at the ring section

16 - Checking the coolant pump Check that there is no play nor resistance at the coolant pump.

102793

Position the ring (3) in the cylinder Push the piston ring (3) to the centre of the cylinder using the piston (4) . Measure the piston ring end clearance using a set of shims (5) . - Compression ring end clearance must be 0.20 to 0.35 mm , - Sealing ring end clearance must be 0.70 to 0.90 mm . - Oil control ring end clearance should be 0.25 to 0.50 mm . 15 - Checking the piston diameter

10027

The piston diameter should be measured at height (X2) = 56 mm . The diameter of the piston must be: - 75.949 ± 0.007 mm for engines K9K 260-270-272274-700-702-704-706-710-714-716-722-750-752762-768-790-792,

10A-223

ENGINE AND LOWER ENGINE ASSEMBLY Piston base cooling jet: Refitting III - EQUIPMENT REQUIRED

Special tooling required Mot. 1494

10A

Tool for refitting piston coolers.

- A hammer. IV - REFITTING THE PISTON BASE COOLING JETS

I - RECOMMENDATIONS FOR REPAIR

IMPORTANT Wear protective gloves during every operation.

15863

The piston base cooling jets must be replaced using the (Mot. 1494) . 1 - Fitting the jets for cylinders 1 and 3

1

3 15573

(6)

orientation of the piston base cooling jets for cylinders 2 and 4,

(7)

orientation of the piston base cooling jets for cylinders 1 and 3,

2 WARNING Check the orientation of the base of the piston base cooling jet which should be aimed towards the centre of the cylinder. 15260

II - PARTS AND CONSUMABLES FOR THE REPAIR Parts always to be replaced

Position plate (1) of tool (Mot. 1494) on the cylinder block without tightening the two bolts (2) . Place the guide rod (3) in the plate (1) .

- the piston base cooling jets,

Position the end of the guide rod in the hole of the piston base cooling jet to centre the plate (1) . Lock the two bolts (2) . Remove the guide rod.

10A-224

ENGINE AND LOWER ENGINE ASSEMBLY Piston base cooling jet: Refitting

10A

2 - Fitting the jets for cylinders 2 and 4

5

1 3

1

2

15260-1

Insert the pushrod in place of the guide rod.

15258-1

Position plate (1) of the (Mot. 1494) on the cylinder block without tightening the two bolts (2) . Place the guide rod (3) in the plate (1) . Position the end of the guide rod in the hole of the piston base cooling jet to centre the plate (1) . Tighten the two bolts (2) . Remove the guide rod.

1

5

15262-1

Insert the jet (4) into the pushrod (5) . Using a hammer, tap the pushrod down until the pushrod collar (5) is touching the plate (1) .

15258

Insert the pushrod in place of the guide rod.

10A-225

ENGINE AND LOWER ENGINE ASSEMBLY Piston base cooling jet: Refitting

15262

Insert the jet (4) into the pushrod (5) . Using a hammer, tap the pushrod down until the pushrod collar (5) is touching the plate (1) . Remove the (Mot. 1494) from the cylinder block.

10A-226

10A

ENGINE AND LOWER ENGINE ASSEMBLY Running gear Refitting

10A

II - PARTS AND CONSUMABLES FOR THE REPAIR

Special tooling required

Parts always to be replaced Mot. 1493-01

Crankshaft bearing centring tool.

Mot. 1319-01

Gauge for measuring height of crankpins.

Mot. 1489

TDC locating pin.

Mot. 1319

Gauge for measuring height of crankpins.

- Con rod cap bolts, - Crankshaft bearing cap bolts. Consumables - Loctite 518, part no. 77 01 421 162 , - Degreasing agent, part no. 77 11 224 559 .

Mot. 1492

Tool for fit ting main bearing shells.

Mot. 1492-03

Tool for fit ting main bearing shells.

Mot. 252-01

Dial gauge support thrust plate.

Mot. 251-01

Dial gauge support.

III - EQUIPMENT REQUIRED

- Female torx socket. - Allen key ( 8 mm ), - Oil can, - Dial gauge, - Flat-blade screwdriver, - Indelible pencil, - Piston ring compressor,

Tightening torquesm

- Piston mounting ring,

the crankshaft bearing cap mounting bolts

25 ± 2.5 Nm + 47°° ± 6°°

the con rod cap mounting bolts

20 ± 2 Nm + 45°° ± 6°°

- Torque/angle wrench, - Torque wrench - Cylinder head bolt tightening gauge (angular measuring type), - Mallet,

I - RECOMMENDATIONS FOR REPAIR

IMPORTANT Wear protective gloves during every operation.

WARNING The sealing surfaces must be clean, dry and free from grease (avoid finger marks). Applying excess sealant could cause it to be squeezed out when parts are tightened. A mixture of sealant and fluid could damage certain components (engine, radiator, etc.) The con rod caps are positioned on the con rod body using the irregularities on the parting line. Impacts or foreign bodies between the contact surfaces between the caps - con rod body could lead to a breakage of the con rod in the short term.

10A-227

ENGINE AND LOWER ENGINE ASSEMBLY Running gear Refitting

10A

Ensure that the crankshaft bearing journals are matched up with the crankshaft bearings on the cylinder block (see 10A, Engine and lower engine assembly, Engine peripherals: Specifications, page 10A-36) .

IV - REFITTING THE ROTATING PARTS

113588

Replace the dipstick guide tube in the cylinder block (if the cylinder block is fitted with one), aligning the orifice (1) of the dipstick guide tube as indicated in the diagram.

16359-1

Position the (Mot. 1493-01) on the cylinder block.

113590

Insert the dipstick guide tube using an 8 mm male Allen key, until the dipstick guide tube extends by 43 mm (the end) (2) over the sealing surface (3) of the cylinder block.

16359

Mount the bearing shell (grooved) (6) in the (Mot. 1493-01) . Push on the bearing until it is pressed against the stop (7) . Repeat this process for other bearings.

10A-228

ENGINE AND LOWER ENGINE ASSEMBLY Running gear Refitting

10A

16358

20159

Position the (Mot. 1493-01) on the crankshaft bearing cap.

Refit the crankshaft thrust washers positioning the grooves of the shims at crankshaft end . Oil the crankshaft bearing shells with engine oil (only the side of the bearing shell that comes in contact with the crankshaft).

16357

Place the bearing shell (non-grooved) (8) in the (Mot. 1493-01) . Push on the bearing until it is pressed against the stop (9) .

10A-229

20158

Degrease the surfaces of the seals (10) of the cylinder block and the crankshaft bearing cap No. 1 using degreaser.

ENGINE AND LOWER ENGINE ASSEMBLY Running gear Refitting

113572

Refit the crankshaft.

10A

113576

Refit the crankshaft bearing caps, ensuring that they are correctly positioned.

113573

Refit the new crankshaft bearing cap mounting bolts.

106965

Tighten to torque in order and to angle the crankshaft bearing cap mounting bolts ( 25 ± 2.5 Nm + 47°° ± 6°° ) .

Apply two drops (11) of LOCTITE 518 of a diameter of 4 mm to camshaft bearing no. 1.

Check that the crankshaft turns freely, with no resistance.

Note: If replacing the con rods, the Parts Department will only supply con rods with a small end diameter of 26 mm . It is therefore essential to check that the gudgeon pin is 26 mm in diameter.

10A-230

ENGINE AND LOWER ENGINE ASSEMBLY Running gear Refitting It is essential to determine the height of the crankpin (X1) in the event of having to replace the con rods, crankshaft, cylinder block. The height (X1) represents the distance between the crankpin at TDC and the surface of the seal on the combustion face of the cylinder block. This measurement enables the piston class to be determined.

10A

Place the dial gauge holder (18) of the (Mot. 1319) with dial gauge in place on the dummy piston (14) . Calibrate the dial gauge (12) on the cylinder block, setting the mid-point between points (13) and (17) . Slide the dial gauge holder to the centre (16) of the depth gauge (15) . Measure the protrusion or recess of the depth gauge. Note the value. Carry out the same procedure for cylinder No. 4. Measuring the crankpin height for cylinders 2 and 3: Position approximately the crankpin for crankshaft No. 2 at Top Dead Centre. Place the dummy piston-depth gauge assembly into cylinder No. 2. Place the dial gauge holder, with dial gauge in place, in the centre of the depth gauge. Gently turn the crankshaft to determine the crankpin top dead centre. Calibrate the dial gauge (12) on the cylinder block, setting the mid-point between points (13) and (17) . Slide the dial gauge holder to the centre (16) of the depth gauge (15) . Measure the protrusion or recess of the depth gauge. Note the value. Carry out the same procedure for cylinder No. 3.

97749

Measuring the crankpin height for cylinders 1 and 4: Insert the appropriate depth gauge of tool (Mot. 1319-01) (15) in the dummy piston (14) of the tool, (Mot. 1319-01) lining up the light of the depth gauge opposite the locking bolt (19) . Tighten the locking bolt (19) . Check that the depth gauge slides freely in the dummy piston. Set the crankshaft at Top Dead Centre using the (Mot. 1489) . Position the dummy piston (14) of the the (Mot. 1319-01) fitted with the depth gauge in cylinder No. 1. Position the depth gauge (15) of the tool, (Mot. 1319-01) pressing on the crankshaft crankpin.

10A-231

Determine the class of piston Add or subtract the values obtained of the length of the depth gauge in order to determine the dimension (X1) . For example: - length of depth gauge = 153.989 mm , - measured protrusion (of the length of the depth gauge beyond the cylinder block) = 0.65 mm , - the dimension (X1) = 153.989 - 0.65 = 153.339 mm (in the event of a recess, the figures must be added). Determine the height of the gudgeon pin using the following formulae: - For engines fitted with a gudgeon pin of diameter 25 mm use formula ( (X1) - 111.535 = the height of the gudgeon pin),

ENGINE AND LOWER ENGINE ASSEMBLY Running gear Refitting

10A

- For engines fitted with a gudgeon pin of diameter 26 mm use formula ( (X1) - 111.576 = the height of the gudgeon pin), Refer to the height classes table for the gudgeon pins in order to choose the correct piston class (see 10A, Engine and lower engine assembly, Engine peripherals: Specifications, page 10A-36) .

21688

Slide the bearing support (22) (positioning the marking "A" (23) as indicated in the diagram) of the tool (Mot. 1492-03) in the groove (24) of the tool base (Mot. 1492) .

15743

17584

Fit the con rod bearings using the (Mot. 1492) (20) and (Mot. 1492-03) (21) . Refitting the con rod bearings on the con rod body.

10A-232

21689

Place the rail (25) of the tool (Mot. 1492-03) on the base.

ENGINE AND LOWER ENGINE ASSEMBLY Running gear Refitting

21690

Mount the con rod body on the base. Check that the lower part (26) of the small end is in contact with the centring pin. Push the rail (in the direction shown by the arrow) until the rail presses against the con rod end.

21691

Mount the bearing shell (27) (with a width of 20.625 mm on the bearing shell support. Push the bearing shell support in the direction shown by the arrow.

10A-233

10A

21692

Bring the bearing shell support to the end of the con rod body base. Remove the support shell from the con rod body. Repeat the operation for the other con rod bodies. Refitting the con rod bearings on the con rod cap.

ENGINE AND LOWER ENGINE ASSEMBLY Running gear Refitting

10A

21693

Position the bearing shell support, aligning the marking "A" or "B" (28) on the side of the cap as follows: - a bearing shell width of 20.625 mm corresponds to "A",

21695

Mount the bearing shell (30) on the bearing shell support. Push the bearing shell support in the direction shown by the arrow.

- a bearing shell width of 17.625 mm corresponds to "B", Mount the con rod cap on the base.

21696

Bring the bearing shell support to the end of the con rod cap base. Remove the bearing shell from the con rod cap. 21694

Push the rail in the direction shown by the arrow until the con rod cap presses against the pins (29) on the base.

10A-234

Repeat the operation for the other con rod caps. Using an indelible pencil, mark the gudgeon pin position in relation to the piston. Lubricate gudgeon pin with engine oil.

ENGINE AND LOWER ENGINE ASSEMBLY Running gear Refitting

10A

Check that the gudgeon pin slides and turns freely in the piston.

12115 113583

Position the mark "V" (31) of the piston and the flat surface (32) of the con rod cap as indicated in the illustration.

21700

Refit the circlip of the gudgeon pin, positioning the opening (34) of the circlip opposite the notch (33) .

10A-235

Note: Ensure the rings are fitted the right way round, with the word TOP pointing upwards.

113580

Refit the piston rings using a piston ring compressor.

ENGINE AND LOWER ENGINE ASSEMBLY Running gear Refitting

10A

Note: Ensure that the piston matches the cylinder block barrel (No.1 at flywheel end) . Ensure the correct con rod-piston orientation, positioning the "V" engraved on the piston crown towards the flywheel .

72552

Fit the shoes such that the gaps are equally spaced around the piston.

113591

Refit the con rod-piston assembly using a piston assembly ring. Mount the con rod heads on the crankshaft crankpins.

16242

Using degreasing agent, degrease the contact surfaces (35) between the cap and body of the con rod. Lubricate with engine oil: - the cylinder block barrels, - the piston rings, - the piston skirts, - the crankshaft crankpins.

10A-236

ENGINE AND LOWER ENGINE ASSEMBLY Running gear Refitting

10A

Note: The measurement is taken along the longitudinal axis of the crankshaft to eliminate play due to the movement of the piston . Calibrate the dial gauge on the cylinder block.

113574

Refit: - the con rod caps, ensuring correct matching, - the new con rod cap mounting bolts. Torque and angle tighten the con rod cap mounting bolts ( 20 ± 2 Nm + 45°° ± 6°° ) . Check that the running gear turns freely, with no resistance. Clean the piston crowns. 20174

Set the crankshaft at Top Dead Centre.

Measure the recess (the sensor of the dial gauge should not be in a valve gap) of the piston which should be: - For engines K9K 260-700-702-704-710-722 fitted with a gudgeon pin 25 mm in diameter the recess is 0.192 ± 0.093 mm , - For engines K9K 260-270-272-700-702-704-706710-722-750-752-790 fitted with a gudgeon pin 26 mm in diameter the recess is 0.154 ± 0.130 mm , - For engines K9K 274-276-712-714-716-718-724728-729-732-760-766-768-792-762-764 fitted with a gudgeon pin 26 mm in diameter the recess is 0.159 ± 0.129 mm , For cylinders No. 2 and No. 3, it is essential to find the Top Dead Centre of the piston before taking the recess measurement.

20175

Mount the contact plate of the (Mot. 252-01) (36) on the cylinder block. Mount the dial gauge support (Mot. 251-01) (37) , with a dial gauge, on the pressure plate.

10A-237

ENGINE AND LOWER ENGINE ASSEMBLY Running gear Refitting

20163

Check the longitudinal clearance of the big ends, which must be between 0.205 and 0.467 mm .

10A-238

10A

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 722 or 750 or 752 or 790 Tightening torquesm

Special tooling required Mot. 1018

Sump plug tool.

Mot. 1586

Tool for fitting PTFE crankshaft seal, timing end.

Mot. 1714

the oil filter holder mounting bolt

Adapter for fitting PTFE crankshaft seal, timing end.

45 ± 4.5 Nm

the acceleration meter

20 ± 2 Nm

the oil pressure switch

30 ± 3 to 35 ± 3.5 Nm 14 ± 2 Nm

the oil filter

Mot. 1585

Tool for fitting PTFE crankshaft seal, flywheel end.

the multifunction support mounting bolts (from 1 to 6 or from 1 to 5)

44 ± 4.4 Nm

Emb. 1596

2 4 mm socket for removing/refitting clutch master cylinder.

multifunction support mounting bolt (7)

21 ± 2.1 Nm

Mot. 1329

Oil filter removing tool (76 mm diameter).

21 ± 2.1 Nm

Mot. 923

Engine lifting ring.

the mounting bolts of the power assisted steering pump or the dummy pulley

Mot. 582-01

Flywheel locking tool.

21 ± 2.1 Nm

Mot. 1677

Flywheel locking tool.

the air conditioning compressor mounting bolts

Emb. 1780

Set of clutch disc centring mandrels.

the alternator mounting bolts

21 ± 2.1 Nm

the coolant / oil heat exchanger mounting bolt

45 ± 4.5 Nm

the oil filter holder mounting bolt

45 ± 4.5 Nm

Tightening torquesm the oil pump mounting bolts

25 ± 2.5 Nm

the oil level sensor

25 ± 2.5 Nm

the crankshaft nose closure unit mounting bolts

11 ± 1.1 Nm

the coolant mounting bolts

11 ± 1.1 Nm

pump

the engine oil sump mounting bolts

14 ± 1.4 Nm

the drain plug of the engine oil sump

20 ± 2 Nm

the coolant pump pipe mounting bolt

22 ± 2.2 Nm

the coolant / oil heat exchanger mounting bolt

45 ± 4.5 Nm

the acceleration meter

20 ± 2 Nm

the oil pressure switch

30 ± 3 to 35 ± 3.5 Nm 14 ± 2 Nm

oil filter flywheel mounting bolts

55 ± 5.5 Nm

the clutch mechanism mounting bolts

M6 to 14 ± 1.4 Nm and bolts M7 to 20 ± 2 Nm

I - RECOMMENDATIONS FOR REPAIR

IMPORTANT Wear protective gloves during every operation.

10A-239

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 722 or 750 or 752 or 790 - The seal of the drain plug of the engine oil sump. Consumables - Degreasing agent, part no. 77 11 224 559 . - Silicone adhesive sealant, part no. 77 11 227 484 , - High-resistance bolt locking product, part no. 77 11 230 112 , III - EQUIPMENT REQUIRED

- Torque/angle wrench, - Torque wrench - Cylinder head bolt tightening gauge (angular measuring type), - Rule, - Male triangular drive drain plug spanner 8 mm ,

18687

- Male torx socket. WARNING

- Oil can,

This type of seal is very delicate. When handling, it is essential to hold the protective piece (21) . It is strictly forbidden to touch seal (22) ; this is to prevent any oil leaks once the oil seal is fitted to the engine.

- Workshop hoist. IV - REASSEMBLING THE CYLINDER BLOCK

The sealing surfaces must be clean, dry and free from grease (avoid finger marks).

Put a little engine oil from an oil can in the oil pump via the oil sump filter.

Applying excess sealant could cause it to be squeezed out when parts are tightened. A mixture of sealant and fluid could damage certain components (engine, radiator, etc.) II - PARTS AND CONSUMABLES FOR THE REPAIR Parts always to be replaced - The crankshaft nose closure unit seal, - The coolant pump seal, - The oil sump mounting seal, - The clutch mechanism (if necessary), - The friction disc (if necessary), - Flywheel mounting bolt - The coolant pump inlet pipe seal, - The oil/coolant heat exchanger seals,

20164

- The crankshaft seal, timing end,

Refit:

- The crankshaft seal, flywheel end,

- the oil pump drive sprocket,

- Oil filter,

- the oil pump chain.

10A-240

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 722 or 750 or 752 or 790

20168

113569

Refit:

Fit a new seal to the crankshaft nose closure unit.

- the oil pump,

Check for the centring dowels on the crankshaft nose closure unit.

- the oil pump mounting bolts (23) , - the oil level sensor (24) . Tighten to torque: - the oil pump mounting bolts ( 25 ± 2.5 Nm ) , - the oil level sensor ( 25 ± 2.5 Nm ) . Apply degreaser to: - the crankshaft nose closure panel, - the coolant pump, - the surface of the seal of the crankshaft nose closure unit on the cylinder block, - the surface of the coolant pump seal on the cylinder block.

10A-241

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 722 or 750 or 752 or 790

12

13 20165

20166

Refit: - the crankshaft nose closure unit, - the crankshaft nose closure unit mounting bolt, Tighten to torque and in order the crankshaft nose closure unit mounting bolts ( 11 ± 1.1 Nm ) . Apply a drop of HIGH-RESISTANCE BOLT LOCKING PRODUCT to the coolant pump mounting bolts. Refit: - the coolant pump fitted with a new seal, - the coolant pump mounting bolts. Tighten to torque and in order the coolant pump mounting bolts ( 11 ± 1.1 Nm ) . Using degreaser, degrease the seal surfaces of the lower part of the cylinder block and the oil sump.

12 20167

Apply: - four beads (12) of SILICONE ADHESIVE SEALANT with a diameter of 5 mm , - two points (13) of SILICONE ADHESIVE SEALANT 5 mm in diameter, at the connection between the crankshaft nose closure panel and the cylinder block.

10A-242

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 722 or 750 or 752 or 790

113492

Refit: - the oil sump mounting seal, - the engine oil sump, 20170

- the oil sump mounting bolts,

20169

12350

When refitting the engine oil sump check that the lugs (14) of the oil splash plate are correctly positioned facing the grooves (15) .

Using a ruler, align the engine oil sump with the cylinder block.

Refit the oil splash plate.

10A-243

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 722 or 750 or 752 or 790

20171

Tighten to torque and in order the engine oil sump mounting bolts ( 14 ± 1.4 Nm ) .

20772

Tighten the threaded rod (3) : - of tool (Mot. 1586) in the crankshaft with an internal thread of M12 , - of tool (Mot. 1714) in the crankshaft with an internal thread of M14 ,

113765

Refit: - a seal (36) on the drain plug of the engine oil sump,

20771

- the drain plug of the engine oil sump, using the (Mot. 1018) .

Insert the spacer (4) of tool (Mot. 1586) in the crankshaft.

Tighten to torque the drain plug of the engine oil sump ( 20 ± 2 Nm ) . Using degreaser, degrease the seal mating face on the crankshaft and the crankshaft nose closure unit.

10A-244

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 722 or 750 or 752 or 790

20770

20768

Fit the protector with the new seal in place on the spacer, taking care not to touch the seal.

20767

Screw on the nut until the cover touches the spacer. 20769

Fit cover (5) and nut (6) (with the thread (7) of the nut towards the outside of the engine).

10A-245

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 722 or 750 or 752 or 790

20766

Remove:

20761

Fit the protector with its seal in place on tool, (Mot. 1585) taking care not to touch the seal.

- the nut, - the cap, - the protector, - the spacer, - the threaded rod. Using degreaser, degrease the seal mating face on the crankshaft and the cylinder block (flywheel end).

20762

Fit cover (9) and nut (10) (with the thread (11) of the nut towards the outside of the engine).

20760

Mount tool (Mot. 1585) on the crankshaft, securing it using bolts (37) .

10A-246

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 722 or 750 or 752 or 790

20763

20765

Remove: - the nut, - the cap, - the protector, - the base. Using degreaser, degrease the seal mating face of the cylinder block where it receives the coolant / oil heat exchanger.

20764

Screw on the nut until the cover touches the cylinder block.

20154

Replace the seal (1) of the coolant / oil heat exchanger, positioning the lip (2) of the joint behind the tabs (3) of the coolant / oil heat exchanger.

10A-247

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 722 or 750 or 752 or 790 1 - For engines fixed to the flywheel side Refit a new o-ring seal to the coolant pump inlet pipe. Put a little soapy water on the o-ring seal of the coolant pump inlet pipe.

20155

Refit: - the coolant pump inlet pipe, - the mounting bolt (38) of the coolant pump inlet pipe, Tighten to torque the coolant pump pipe mounting bolt ( 22 ± 2.2 Nm ) . Position the coolant / oil heat exchanger (fitted with its coolant hoses), enclosing the coolant hoses in the inlet pipe of the coolant pump, in order to position correctly the coolant / oil heat exchanger. Apply two drops of HIGH-RESISTANCE BOLT LOCKING PRODUCT to the coolant / oil heat exchanger mounting bolt. Refit: - the coolant / oil heat exchanger, - the mounting bolt (39) of the oil / coolant heat exchanger, Tighten to torque the coolant / oil heat exchanger mounting bolt ( 45 ± 4.5 Nm ) . Using degreaser, degrease the seal mating face of the coolant / oil heat exchanger where it receives the oil filter holder.

10A-248

10A

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 722 or 750 or 752 or 790

20153

Replace the seals (4) and (5) . Refit the oil filter holder, positioning the lug (6) in the hole (7) on the coolant / oil heat exchanger.

10A-249

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 722 or 750 or 752 or 790

20157

19704

Refit: - the acceleration meter (40) , - the oil pressure switch (41) . Tighten to torque: - the oil filter holder mounting bolt ( 45 ± 4.5 Nm ), - the acceleration meter ( 20 ± 2 Nm ) using the tool (Emb. 1596) , - the oil pressure switch ( 30 ± 3 to 35 ± 3.5 Nm ) . Lubricate the oil filter seal with new engine oil. Refit the oil filter using the (Mot. 1329) . Tighten to torque the oil filter ( 14 ± 2 Nm ) .

111057

Refit: - the multifunction support, - the multifunction support mounting bolts. Tighten to torque and in order the multifunction support mounting bolts (from 1 to 6 or from 1 to 5) ( 44 ± 4.4 Nm ) . Torque tighten the multifunction support mounting bolt (7) ( 21 ± 2.1 Nm ) .

10A-250

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 722 or 750 or 752 or 790 Tighten to torque: - the mounting bolts of the power assisted steering pump or the dummy pulley ( 21 ± 2.1 Nm ) , - the air conditioning compressor mounting bolts ( 21 ± 2.1 Nm ) , - the alternator mounting bolts ( 21 ± 2.1 Nm ) . 2 - For engines fixed to the oil filter side In order to position correctly the coolant / oil heat exchanger on the cylinder block it is essential to remove the cylinder block from the engine support using tool (Mot. 923) and a workshop hoist. Remove the engine spindle from the cylinder block. Refit: - the coolant pump inlet pipe, 107853

- the mounting bolt of the coolant pump inlet pipe.

111079

20155

- the power assisted steering pump or the dummy pulley,

Position the coolant / oil heat exchanger (fitted with its coolant hoses), enclosing the coolant hoses in the inlet pipe of the coolant pump, in order to position correctly the coolant / oil heat exchanger.

Refit:

- the mounting bolts (48) of the power assisted steering pump or the dummy pulley, - the air conditioning compressor (if fitted),

Apply two drops of HIGH-RESISTANCE BOLT LOCKING PRODUCT to the coolant / oil heat exchanger mounting bolt.

- the air conditioning compressor mounting bolts (45) ,

Tighten to torque the coolant / oil heat exchanger mounting bolt ( 45 ± 4.5 Nm ) .

- the alternator,

Using degreaser, degrease the seal mating face of the coolant / oil heat exchanger where it receives the oil filter holder.

- the alternator mounting bolts (47) .

10A-251

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 722 or 750 or 752 or 790

20153

Replace the seals (4) and (5) . Refit the oil filter holder, positioning the lug (6) in the hole (7) on the coolant / oil heat exchanger.

10A-252

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 722 or 750 or 752 or 790

20157

101356

Refit: - the acceleration meter (40) ,

Note:

- the oil pressure switch (41) .

Certain flywheels have a shim (49) . It is essential to position the chamfer (50) of the shim on the flywheel side .

Tighten to torque: - the oil filter holder mounting bolt ( 45 ± 4.5 Nm ), - the acceleration meter ( 20 ± 2 Nm ) using the tool (Emb. 1596) , - the oil pressure switch ( 30 ± 3 to 35 ± 3.5 Nm ) . Remove the coolant pump inlet pipe. Refit: - the engine spindle onto the cylinder block. - the cylinder block onto the engine support. Lubricate the oil filter seal with new engine oil. Refit the oil filter using the tool (Mot. 1329) . Tighten to torque the oil filter ( 14 ± 2 Nm ) .

10A-253

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 722 or 750 or 752 or 790

20172

103285

Refit:

Refit:

- the flywheel,

- the clutch pressure plate,

- the new flywheel mounting bolts,

- the clutch mechanism mounting bolts.

- engine flywheel locking tool (Mot. 582-01) or (Mot. 1677) .

Gradually tighten the mounting bolts of the clutch pressure plate.

Tighten to torque and in order the flywheel mounting bolts ( 55 ± 5.5 Nm ) .

Tighten to torque the clutch mechanism mounting bolts ( M6 to 14 ± 1.4 Nm and bolts M7 to 20 ± 2 Nm ) .

Using degreasing agent, degrease the friction face on the flywheel. Refit the friction disc (aligning it correctly). Centre the friction disc using tool (Emb. 1780) . Using degreasing agent, degrease the friction face on the clutch mechanism.

10A-254

Remove engine flywheel locking tool (Mot. 582-01) or. (Mot. 1677) .

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 274 or 276 or 712 or 714 or 716 or 718 or 724 or 728 or 729 or 760 or 762 or 766 or 768 Special tooling required

Tightening torquesm 14 ± 2 Nm

Mot. 1018

Sump plug tool.

oil filter

Mot. 1586

Tool for fitting PTFE crankshaft seal, timing end.

the multifunction support mounting bolts (1 to 6)

44 ± 4.4 Nm

Mot. 1714

Adapter for fitting PTFE crankshaft seal, timing end.

multifunction support mounting bolt (7)

21 ± 2.1 Nm

Tool for fitting PTFE crankshaft seal, flywheel end.

the mounting bolts of the power assisted steering pump or the dummy pulley

21 ± 2.1 Nm

Mot. 1585

Emb. 1596

2 4 mm socket for removing/refitting clutch master cylinder.

the air conditioning compressor mounting bolts

21 ± 2.1 Nm

Mot. 1329

Oil filter removing tool (76 mm diameter).

the alternator mounting bolts

21 ± 2.1 Nm

Mot. 1677

Flywheel locking tool.

flywheel mounting bolts

55 ± 5.5 Nm

Emb. 1780

Set of clutch disc centring mandrels.

the clutch mechanism mounting bolts

M6 to 14 ± 1.4 Nm and bolts M7 to 20 ± 2 Nm

Tightening torquesm oil pump mounting bolts

25 ± 2.5 Nm

the crankshaft nose closure unit mounting bolts

11 ± 1.1 Nm

the coolant mounting bolts

pump

11 ± 1.1 Nm

the engine oil sump mounting bolts

14 ± 1.4 Nm

the drain plug of the engine oil sump

20 ± 2 Nm

the coolant pump inlet pipe mounting bolt

22 ± 2.2 Nm

the oil level sensor

25 ± 2.5 Nm

the acceleration meter

I - RECOMMENDATIONS FOR REPAIR

IMPORTANT Wear protective gloves during every operation.

20 ± 2 Nm

the coolant/oil heat exchanger mounting bolt

45 ± 4.5 Nm

oil filter holder mounting bolt

45 ± 4.5 Nm

10A-255

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 274 or 276 or 712 or 714 or 716 or 718 or 724 or 728 or 729 or 760 or 762 or 766 or 768 - The seal of the drain plug of the engine oil sump. Consumables - Degreasing agent, part no. 77 11 224 559 . - Silicone adhesive sealant, part no. 77 11 227 484 , - High-resistance bolt locking product, part no. 77 11 230 112 , III - EQUIPMENT REQUIRED

- Torque/angle wrench, - Torque wrench - Cylinder head bolt tightening gauge (angular measuring type), - Rule, 18687

- Male triangular drive drain plug spanner 8 mm , - Male torx socket.

WARNING This type of seal is very delicate. When handling, it is essential to grip protective piece (21) . It is strictly forbidden to touch seal; (22) this is to prevent any oil leaks once the oil seal is fitted to the engine.

- Oil can, IV - REASSEMBLING THE CYLINDER BLOCK

The sealing surfaces must be clean, dry and free from grease (avoid finger marks).

Put a little engine oil from an oil can in the oil pump via the oil sump filter.

Applying excess sealant could cause it to be squeezed out when parts are tightened. A mixture of sealant and fluid could damage certain components (engine, radiator, etc.) II - PARTS AND CONSUMABLES FOR THE REPAIR Parts always to be replaced - The crankshaft nose closure unit seal, - The coolant pump seal, - The oil sump mounting seal, - The clutch mechanism (if necessary), - The friction disc (if necessary), - Flywheel mounting bolt - The coolant pump inlet pipe seal, 20164

- The oil/coolant heat exchanger seals, - The crankshaft seal, timing end,

Refit:

- The crankshaft seal, flywheel end,

- the oil pump drive sprocket,

- Oil filter,

- the oil pump chain.

10A-256

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 274 or 276 or 712 or 714 or 716 or 718 or 724 or 728 or 729 or 760 or 762 or 766 or 768

113577

Refit the oil pump. Tighten to torque the oil pump mounting bolts ( 25 ± 2.5 Nm ) . 20165

Apply degreaser to: Refit:

- the crankshaft nose closure panel,

- the crankshaft nose closure panel,

- the coolant pump,

- the crankshaft nose closure unit mounting bolt,

- the surface of the seal of the crankshaft nose closure unit on the cylinder block,

Tighten to torque and in order the crankshaft nose closure unit mounting bolts ( 11 ± 1.1 Nm ) .

- the surface of the coolant pump seal on the cylinder block.

Apply a drop of HIGH-RESISTANCE BOLT LOCKING PRODUCT to the coolant pump mounting bolts. Refit: - the coolant pump fitted with a new seal, - the coolant pump mounting bolts. Tighten to torque and in order the coolant pump mounting bolts ( 11 ± 1.1 Nm ) . Using degreaser, degrease the seal surfaces of the lower part of the cylinder block and the oil sump.

113569

Fit a new seal to the crankshaft nose closure unit. Check for the centring dowels on the crankshaft nose closure unit.

10A-257

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 274 or 276 or 712 or 714 or 716 or 718 or 724 or 728 or 729 or 760 or 762 or 766 or 768

K9K, and 712 or 728

12

13 20166

20170

12 20167

Apply: - four beads (12) of SILICONE ADHESIVE SEALANT with a diameter of 5 mm , - two points (13) of SILICONE ADHESIVE SEALANT 5 mm in diameter, at the connection between the crankshaft nose closure panel and the cylinder block.

10A-258

20169

When refitting the engine oil sump check that the tabs (38) of the oil splash plate are correctly positioned facing the grooves (39) . Refit the oil splash plate.

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 274 or 276 or 712 or 714 or 716 or 718 or 724 or 728 or 729 or 760 or 762 or 766 or 768

113492

Refit: - the oil sump mounting seal, - the engine oil sump, - the oil sump mounting bolts,

20171

Tighten to torque and in order the engine oil sump mounting bolts ( 14 ± 1.4 Nm ) .

12350

Using a ruler, align the engine oil sump with the cylinder block.

113765

Refit: - a seal (36) on the drain plug of the engine oil sump, - the drain plug of the engine oil sump, using the (Mot. 1018) . Tighten to torque the drain plug of the engine oil sump ( 20 ± 2 Nm ) . Using degreaser, degrease the seal mating face on the crankshaft and the crankshaft nose closure unit.

10A-259

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 274 or 276 or 712 or 714 or 716 or 718 or 724 or 728 or 729 or 760 or 762 or 766 or 768

3 20772

Tighten the threaded rod (3) : - of the (Mot. 1586) in the crankshaft with a M12 thread hole,

20770

Fit the protector with the new seal in place on the spacer, taking care not to touch the seal.

- of the (Mot. 1714) in the crankshaft with a M14 thread hole,

4

20769

Fit cover (5) and nut (6) (with the thread (7) of the nut towards the outside of the engine). 20771

Insert the spacer (4) of the (Mot. 1586) in the crankshaft.

10A-260

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 274 or 276 or 712 or 714 or 716 or 718 or 724 or 728 or 729 or 760 or 762 or 766 or 768

20768

20766

Remove - the nut, - the cap, - the protector, - the spacer, - the threaded rod. Using degreaser, degrease the seal mating face on the crankshaft and the cylinder block (flywheel end).

20767

Screw on the nut until the cover touches the spacer.

20760

Mount the (Mot. 1585) on the crankshaft, securing it using bolts (37) .

10A-261

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 274 or 276 or 712 or 714 or 716 or 718 or 724 or 728 or 729 or 760 or 762 or 766 or 768

20761

20763

Fit the protector with its seal in place on the (Mot. 1585) , taking care not to touch the seal.

20764

20762

Fit cover (9) and nut (10) (with the thread (11) of the nut towards the outside of the engine).

10A-262

Screw on the nut until the cover touches the cylinder block.

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 274 or 276 or 712 or 714 or 716 or 718 or 724 or 728 or 729 or 760 or 762 or 766 or 768

20765

107858

Remove:

Refit:

- the nut,

- the coolant pump inlet pipe,

- the cap,

- the mounting bolt (40) of the coolant pump inlet pipe,

- the protector,

- the oil level sensor (41) ,

- the base. Refit a new O-ring seal to the coolant pump inlet pipe. Put a little soapy water on the O-ring seal of the coolant pump inlet pipe.

- the acceleration meter (42) . Tighten to torque: - the coolant pump inlet pipe mounting bolt ( 22 ± 2.2 Nm ) . - the oil level sensor ( 25 ± 2.5 Nm ) . - the acceleration meter ( 20 ± 2 Nm ) using the (Emb. 1596) . Using degreaser, degrease the seal mating face of the cylinder block where it receives the coolant / oil heat exchanger.

10A-263

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 274 or 276 or 712 or 714 or 716 or 718 or 724 or 728 or 729 or 760 or 762 or 766 or 768 Tighten to torque the coolant/oil heat exchanger mounting bolt ( 45 ± 4.5 Nm ) . Using degreaser, degrease the seal mating face of the coolant / oil heat exchanger where it receives the oil filter holder. Refit: - a new seal on the oil filter holder, - a new seal on the oil filter holder mounting bolt.

107306

107856

Refit: - the oil filter holder, - the oil filter holder mounting bolt Tighten to torque the oil filter holder mounting bolt ( 45 ± 4.5 Nm ) . Lubricate the oil filter seal with new engine oil. Refit the oil filter using the (Mot. 1329) . Tighten to torque the oil filter ( 14 ± 2 Nm ) . 113482

Fit the new seals (43) and (44) on the coolant/oil heat exchanger. Apply soapy water to the two seals (43) in contact with the inlet pipe of the coolant pump. Apply two drops of HIGH-RESISTANCE BOLT LOCKING PRODUCT to the coolant/oil heat exchanger mounting bolt. Refit: - the coolant/oil heat exchanger, - the mounting bolt of the oil/coolant heat exchanger,

10A-264

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 274 or 276 or 712 or 714 or 716 or 718 or 724 or 728 or 729 or 760 or 762 or 766 or 768

107855

Refit: - the multifunction support, - the multifunction support mounting bolts. Tighten to torque and in order the multifunction support mounting bolts (1 to 6) ( 44 ± 4.4 Nm ) . Torque tighten the multifunction support mounting bolt (7) ( 21 ± 2.1 Nm ) .

10A-265

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 274 or 276 or 712 or 714 or 716 or 718 or 724 or 728 or 729 or 760 or 762 or 766 or 768 Tighten to torque: - the mounting bolts of the power assisted steering pump or the dummy pulley ( 21 ± 2.1 Nm ) , - the air conditioning compressor mounting bolts ( 21 ± 2.1 Nm ) , - the alternator mounting bolts ( 21 ± 2.1 Nm ) .

107853

101356

Note: Certain flywheels have a shim (49) . It is essential to position the chamfer (50) of the shim on the flywheel side .

111079

Refit: - the power assisted steering pump or the dummy pulley, - the mounting bolts (48) of the power assisted steering pump or the dummy pulley, - the air conditioning compressor (if fitted), - the air conditioning compressor mounting bolts (45) , - the alternator, - the alternator mounting bolts (47) .

10A-266

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 274 or 276 or 712 or 714 or 716 or 718 or 724 or 728 or 729 or 760 or 762 or 766 or 768

20172

103285

Refit:

Refit:

- the flywheel,

- the clutch pressure plate,

- the new flywheel mounting bolts,

- the clutch mechanism mounting bolts.

- the engine flywheel locking tool (Mot. 1677) .

Gradually tighten the mounting bolts of the clutch pressure plate.

Tighten to torque and in order the flywheel mounting bolts ( 55 ± 5.5 Nm ) . Using degreasing agent, degrease the friction face on the flywheel.

Tighten to torque the clutch mechanism mounting bolts ( M6 to 14 ± 1.4 Nm and bolts M7 to 20 ± 2 Nm ) . Remove flywheel immobiliser tool (Mot. 1677) .

Refit the friction plate (aligning it correctly). Centre the friction plate using the (Emb. 1780) . Using degreasing agent, degrease the friction face on the clutch mechanism.

10A-267

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 732 or 764 Special tooling required

Tightening torquesm

Mot. 1018

Sump plug tool.

Mot. 1586

Tool for fitting PTFE crankshaft seal, timing end.

Mot. 1714

the coolant/oil heat exchanger mounting bolt

45 ± 4.5 Nm

oil filter holder mounting bolt

45 ± 4.5 Nm

Adapter for fitting PTFE crankshaft seal, timing end.

Mot. 1585

Tool for fitting PTFE crankshaft seal, flywheel end.

14 ± 2 Nm

oil filter the multifunction support mounting bolts (1 to 6)

44 ± 4.4 Nm

21 ± 2.1 Nm

Mot. 1677

Flywheel locking tool.

multifunction support mounting bolt (7)

Emb. 1780

Set of clutch disc centring mandrels.

air conditioning compressor mounting bolts

21 ± 2.1 Nm

Emb. 1761

Clutch pressure plate removal/refitting kit

the alternator mounting bolts

21 ± 2.1 Nm

Mot. 1329

Oil filter removing tool (76 mm diameter).

I - RECOMMENDATIONS FOR REPAIR

IMPORTANT

Tightening torquesm oil pump mounting bolts

25 ± 2.5 Nm

the crankshaft nose closure unit mounting bolts

11 ± 1.1 Nm

the coolant mounting bolts

pump

11 ± 1.1 Nm

the engine oil sump mounting bolts

14 ± 1.4 Nm

the drain plug of the engine oil sump

20 ± 2 Nm

the flywheel mounting bolts

2 ± 20 Nm + 36˚ ± 6˚

clutch mechanism bolt

14 ± 1.4 Nm

the clutch mechanism bolt

14 ± 1.4 Nm

the coolant pump inlet pipe mounting bolt

22 ± 2.2 Nm

the oil level sensor

25 ± 2.5 Nm

10A-268

Wear protective gloves during every operation.

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 732 or 764 - The seal of the drain plug of the engine oil sump. Consumables - Degreasing agent, part no. 77 11 224 559 . - Silicone adhesive sealant, part no. 77 11 227 484 , - High-resistance bolt locking product, part no. 77 11 230 112 , III - EQUIPMENT REQUIRED

- Torque/angle wrench, - Torque wrench - Cylinder head bolt tightening gauge (angular measuring type), - Ruler, - Square section drain wrench, male 8 mm , 18687

- Male torx socket. - Oil can,

WARNING This type of seal is very delicate. When handling, it is essential to grip protective piece. (2 1) It is strictly forbidden to touch seal, (22) this is to prevent any oil leaks once the oil seal is fitted to the engine.

IV - REASSEMBLING THE CYLINDER BLOCK Put a little engine oil from an oil can in the oil pump via the oil sump filter.

The sealing surfaces must be clean, dry and free from grease (avoid finger marks). Applying excess sealant could cause it to be squeezed out when parts are tightened. A mixture of sealant and fluid could damage certain components (engine, radiator, etc.) II - PARTS AND CONSUMABLES FOR THE REPAIR Parts always to be replaced - The crankshaft nose closure unit seal, - The coolant pump seal,

113577

- The oil sump mounting seal,

Refit:

- The clutch mechanism (if necessary),

- the oil pump drive sprocket,

- The friction disc (if necessary),

- the oil pump complete with its chain,

- Flywheel mounting bolt

- the oil pump mounting bolts.

- The coolant pump inlet pipe seal, - The oil / coolant heat exchanger seals,

Tighten to torque the oil pump mounting bolts ( 25 ± 2.5 Nm ) .

- The crankshaft, timing end, mounting seal,

Apply degreaser to:

- The crankshaft, flywheel end, mounting seal,

- the crankshaft nose closure panel,

- Oil filter,

- the coolant pump,

10A-269

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 732 or 764 - the surface of the seal of the crankshaft nose closure unit on the cylinder block, - the surface of the coolant pump seal on the cylinder block.

113570

Refit: - the crankshaft nose closure panel, 113569

Fit a new seal to the crankshaft nose closure unit. Check for the centring dowels on the crankshaft nose closure unit.

10A-270

- the crankshaft nose closure unit mounting bolt, Tighten to torque and in order the crankshaft nose closure unit mounting bolts ( 11 ± 1.1 Nm ) . Apply a drop of HIGH-RESISTANCE BOLT LOCKING PRODUCT to the coolant pump mounting bolts.

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 732 or 764

113571

20166

Refit: - the coolant pump fitted with a new seal, - the coolant pump mounting bolts. Tighten to torque and in order the coolant pump mounting bolts ( 11 ± 1.1 Nm ) . Using degreaser, degrease the seal surfaces of the lower part of the cylinder block and the oil sump.

20167

Apply: - four beads (8) of SILICONE ADHESIVE SEALANT with a diameter of 5 mm , - two points (7) of SILICONE ADHESIVE SEALANT 5 mm in diameter, at the connection between the crankshaft nose closure panel and the cylinder block.

10A-271

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 732 or 764

113492

Refit:

113492

Tighten to torque and in order the engine oil sump mounting bolts ( 14 ± 1.4 Nm ) .

- the oil sump mounting seal, - the engine oil sump, - the oil sump mounting bolts,

113765

Refit: - a seal (36) on the drain plug of the engine oil sump, 12350

Using a ruler, align the engine oil sump with the cylinder block.

- the drain plug of the engine oil sump, using the (Mot. 1018) . Tighten to torque the drain plug of the engine oil sump ( 20 ± 2 Nm ) . Using degreaser, degrease the seal mating face on the crankshaft and the crankshaft nose closure unit.

10A-272

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 732 or 764

20772

Tighten the threaded rod (23) : - of tool (Mot. 1586) in the crankshaft with an internal thread of M12 ,

20770

Fit the protector with the new seal in place on the spacer, taking care not to touch the seal.

- of tool (Mot. 1714) in the crankshaft with an internal thread of M14 ,

20769

Fit cover (25) and nut (26) (with the thread (27) of the nut towards the outside of the engine). 20771

Insert the spacer (24) of tool (Mot. 1586) in the crankshaft.

10A-273

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 732 or 764

20768

20766

Remove: - the nut, - the cap, - the protector, - the spacer, - the threaded rod. Using degreaser, degrease the seal mating face on the crankshaft and the cylinder block (flywheel end).

20767

Screw on the nut until the cover touches the spacer.

20760

Mount the (Mot. 1585) on the crankshaft, securing it using bolts (28) .

10A-274

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 732 or 764

20761

20763

Fit the protector with its seal in place on tool, (Mot. 1585) taking care not to touch the seal.

20764

20762

Fit cover (29) and nut (30) (with the thread (31) of the nut towards the outside of the engine).

10A-275

Tighten the nut until the cover touches the cylinder block.

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 732 or 764

113490

Refit the friction disc (aligning it correctly). Centre the friction disc using the (Emb. 1780) .

20765

Using degreasing agent, degrease the friction face on the clutch mechanism.

Remove: - the nut, - the cap, - the protector, - the base.

113489

Refit the clutch mechanism. Position the mounting bolts of the clutch mechanism using tool (Emb. 1761) (32) . Position the clutch mechanism flat against the flywheel, tightening the nuts of tool (Emb. 1761) . 113488

Refit the clutch mechanism mounting bolts.

Refit:

Tighten to torque the clutch mechanism bolt ( 14 ± 1.4 Nm ) .

- the flywheel,

Remove the (Emb. 1761) .

- the new flywheel mounting bolts,

Refit the three clutch mechanism mounting bolts.

- engine flywheel locking tool (Mot. 1677) .

Tighten to torque the clutch mechanism bolt ( 14 ± 1.4 Nm ) .

Tighten to torque and in order the flywheel mounting bolts ( 2 ± 20 Nm + 36˚ ± 6˚ ) . Using degreasing agent, degrease the friction face on the flywheel.

10A-276

Remove flywheel immobiliser tool (Mot. 1677) . Refit a new o-ring seal to the coolant pump inlet pipe.

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 732 or 764 Put a little soapy water on the o-ring seal of the coolant pump inlet pipe.

107306 113481

Refit: - the coolant pump inlet pipe, - the mounting bolt (33) of the coolant pump inlet pipe, - the oil level sensor (34) . Tighten to torque: - the coolant pump inlet pipe mounting bolt ( 22 ± 2.2 Nm ) , - the oil level sensor ( 25 ± 2.5 Nm ) . Using degreaser, degrease the seal mating face of the cylinder block where it receives the coolant / oil heat exchanger.

113482

Fit the new seals (35) and (37) on the coolant / oil heat exchanger. Apply soapy water to the two seals (35) in contact with the inlet pipe of the coolant pump. Apply two drops of HIGH-RESISTANCE BOLT LOCKING PRODUCT to the coolant / oil heat exchanger mounting bolt. Refit: - the coolant/oil heat exchanger, - the mounting bolt of the oil/coolant heat exchanger,

10A-277

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting

10A

K9K, and 732 or 764 Tighten to torque the coolant/oil heat exchanger mounting bolt ( 45 ± 4.5 Nm ) . Using degreaser, degrease the seal mating face of the coolant/oil heat exchanger where it receives the oil filter holder. Refit: - a new seal on the oil filter holder, - a new seal on the oil filter holder mounting bolt.

113485

Refit: - the multifunction support, - the multifunction support mounting bolts. Tighten to torque and in order the multifunction support mounting bolts (1 to 6) ( 44 ± 4.4 Nm ) .

113483

Torque tighten the multifunction support mounting bolt (7) ( 21 ± 2.1 Nm ) .

Refit: - the oil filter holder, - the oil filter holder mounting bolt Tighten to torque the oil filter holder mounting bolt ( 45 ± 4.5 Nm ) . Lubricate the oil filter seal with new engine oil. Refit the oil filter using the (Mot. 1329) . Tighten to torque the oil filter ( 14 ± 2 Nm ) .

113486

Refit: - the air conditioning compressor, - the air conditioning compressor mounting bolts.

10A-278

ENGINE AND LOWER ENGINE ASSEMBLY Cylinder block: Refitting K9K, and 732 or 764 Tighten to torque the air conditioning compressor mounting bolts ( 21 ± 2.1 Nm ) .

113487

Refit: - the alternator, - the alternator mounting bolts. Tighten to torque the alternator mounting bolts ( 21 ± 2.1 Nm ) .

10A-279

10A

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790 Special tooling required

Tightening torquesm

Mot. 1430

Set of 5 crankshaft and camshaft pulley timing pins.

Mot. 1489

TDC locating pin.

the tensioning roller bolt the TDC pin plug cap

Tightening torquesm the cylinder mounting bolts

head

25 ± 2.5 Nm

the cylinder mounting bolts

head

255˚ ± 10˚

27 ± 2.7 Nm 20 ± 2 Nm

the cylinder head suspended mounting bolts

21 ± 2.1 Nm

the high-pressure pump position sensor bolt

8 ± 0.8 Nm

I - RECOMMENDATIONS FOR THE REPAIR OF THE CYLINDER HEAD

the rocker cover bolts

12 ± 1.2 Nm

the turbocharger oil return pipe mounting bolts

12 ± 1.2 Nm

Wear protective gloves during every operation.

the turbocharger mounting nuts

26 ± 2.6 Nm

the catalytic converter stay mounting bolts on the engine

44 ± 4.4 Nm

WARNING When handling the cylinder head gasket, it is essential to hold the cylinder head gasket by the part between barrels.

the catalytic converter stay mounting bolts on the catalytic converter

26 ± 2.6 Nm

the mounting bolt of the turbocharger oil supply pipe (turbocharger end)

23 ± 2.3 Nm

the turbocharger oil supply pipe mounting nut (cylinder head end)

collar nut 35 ± 3.5 Nm or no collar nut 23 ± 2.3 Nm

the inner timing cover mounting bolts

9 ± 0.9 Nm

the tensioning roller bolt

27 ± 2.7 Nm

the crankshaft accessories pulley M12 mounting bolt

60 ± 6 Nm + 100˚ ± 10˚

the crankshaft accessories pulley M14 mounting bolt

120 ± 12 Nm + 95˚ ± 15˚

IMPORTANT

The sealing surfaces must be clean, dry and free from grease (avoid finger marks). Applying excess sealant could cause it to be squeezed out when parts are tightened. A mixture of sealant and fluid could damage certain components (engine, radiator, etc.) To obtain correct tightening of the cylinder head bolts, remove any oil from the cylinder head mounting holes using a syringe. Do not retighten the cylinder head bolts after applying this procedure. Do not grease the new cylinder head mounting bolts.

II - PARTS AND CONSUMABLES FOR THE REPAIR Parts always to be replaced for the cylinder head - The cylinder head gasket, - The cylinder head bolts, - The rocker cover gasket, - The gasket between the exhaust manifold and the turbocharger, - The seals on the turbocharger oil return pipe,

10A-280

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790 - The catalytic converter seal, Consumables - Degreasing agent, part no. 77 11 224 559 .

8

4

1

5

9

7

3

2

6

10

- High-resistance bolt locking product, part no. 77 11 230 112 , - Silicone adhesive sealant, part no. 77 11 227 484 . III - EQUIPMENT REQUIRED FOR THE CYLINDER HEAD

- Torque/angle wrench, - Torque wrench

19712

- Cylinder head bolt tightening gauge (angular measuring type),

Torque tighten in order the cylinder head mounting bolts ( 25 ± 2.5 Nm ) .

- Oil can,

Check that all the cylinder head mounting bolts are correctly tightened to (25 ± 2.5 Nm) .

- Female torx socket ( 14 ),

Tighten in order and to torque the cylinder head mounting bolts ( 255˚ ± 10˚ ) .

- Protective gloves.

Using degreasing agent, degrease the surface of the rocker cover bearing on the cylinder head.

IV - REFITTING THE CYLINDER HEAD Position the pistons at mid-stroke.

Fit a new seal on the rocker cover.

Apply degreaser to: - the combustion side of the cylinder head, - the combustion face of the cylinder block. Check for the cylinder head centring dowels on the cylinder block.

1

1

Refit the cylinder head gasket (positioning the TOP at the top) on the cylinder block. Remove the cylinder head from the cylinder head support. Refit: - the cylinder head, - the new cylinder head mounting bolts.

19712-1

Apply four beads (1) of SILICONE SEALANT with a diameter of 2 mm . Refit: - the rocker cover, - the rocker cover mounting bolts.

10A-281

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790

5 1 6 3 2 7

4

8 19711

Tighten to torque and in order the rocker cover bolts ( 12 ± 1.2 Nm ) . Fit the new seals on the turbocharger oil return pipe. Lubricate the O-ring seals of the turbocharger oil return pipe with engine oil.

19708

Refit the turbocharger-catalytic converter assembly. Fully insert the turbocharger oil return pipes on to the cylinder block at (2) . Refit: - the catalytic converter mounting stay, - the catalytic converter stay mounting bolts. Tighten to torque: - the turbocharger mounting nuts ( 26 ± 2.6 Nm ) , - the catalytic converter stay mounting bolts on the engine ( 44 ± 4.4 Nm ) (17) , - the catalytic converter stay mounting bolts on the catalytic converter ( 26 ± 2.6 Nm ) (4) , Put a little engine oil from an oil can in the oil circuit of the turbocharger.

102078

Tighten to torque the turbocharger oil return pipe mounting bolts ( 12 ± 1.2 Nm ) . Fit a new seal between the exhaust manifold and the turbocharger.

10A-282

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790

5

19709

Refit the turbocharger oil supply pipe. Screw in place each mounting of the turbocharger oil supply pipe. 114285

Tighten to torque: - the mounting bolt of the turbocharger oil supply pipe (turbocharger end) ( 23 ± 2.3 Nm ) at (3) ,

Note: These two turbocharger oil supply pipes may be used on the same engine. The tightening torque of the end pieces (20) on the cylinder head is different, depending on the following:

- the turbocharger oil supply pipe mounting nut (cylinder head end) ( collar nut 35 ± 3.5 Nm or no collar nut 23 ± 2.3 Nm ) at (5) .

- if the end piece is shouldered (19) , in this case there will be no need to place the highresistance bolt locking product on the end piece thread,

Refit: - the oil vapour rebreather pipe, - the new turbocharger air ducts.

- if the end piece is not shouldered (18) , in this case it is essential to place the high-resistance bolt locking product on the end piece thread,

19707

Refit the air filter unit.

10A-283

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790 VI - PARTS AND CONSUMABLES FOR THE REPAIR Pièces à remplacer systématiquement pour la distribution - Timing belt, - Timing belt tensioning roller, - Crankshaft accessories pulley bolt. Ingrédients - Silicone adhesive sealant, part no. 77 11 227 484 - Degreasing agent, part no. 77 11 224 559 . VII - EQUIPMENT REQUIRED FOR THE TIMING GEAR

- Protective gloves, 19710

- Allen key ( 6 mm ),

Refit:

- Female torx socket ( 14 ),

- the inner timing cover (moving the alternator if necessary),

- Offset spanner ( 18 mm ),

- the inner timing cover mounting bolts.

- Torque wrench

Tighten to torque the inner timing cover mounting bolts ( 9 ± 0.9 Nm ) .

- Cylinder head bolt tightening gauge (angular measuring type).

V - RECOMMENDATIONS FOR THE REPAIR OF THE TIMING GEAR

IMPORTANT Wear protective gloves during every operation.

WARNING The belt must be replaced with a new one if it has been removed. Never turn the engine in the opposite direction to its normal operating direction. Do not run the engine without the accessories belt so as not to damage the crankshaft accessories pulley. When replacing the belt, always replace the tensioning rollers and fixed rollers. It is essential to remove the grease from the end of the crankshaft, the camshaft timing sprocket and the bearing face of the crankshaft accessories pulley. This is to avoid timing slippage.

10A-284

- Torque/angle wrench,

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790 VIII - REFITTING THE TIMING BELT

1

104703

Apply degreaser to: - the end of the crankshaft (timing end), - the timing sprocket bearing faces and bore at (1) , - the contact surfaces of the crankshaft accessories pulley.

10A-285

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790

5

6

4 3 2

7

19656-2

Refit: - the crankshaft timing sprocket, - the timing tensioning roller. Position the spigot (2) of the tensioning roller in the groove (3) of the cylinder head. Insert pin (Mot. 1430) in the cylinder head and camshaft pulley holes at (4) . Turning the camshaft using an 18 mm offset spanner, if necessary. Check that high-pressure pump pulley marking (5) is opposite the bolt head (6) .

14489

Position the crankshaft so that is presses against the TDC setting pin (Mot. 1489) (crankshaft groove (7) must be at the top).

10A-286

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790

8

19657

19658

Fit the timing belt, starting with the crankshaft sprocket, aligning the marks on the belt with those on the camshaft and high-pressure pump pulleys.

Position the tensioning roller adjustable index marker (8) opposite the spigot, turning the eccentric cam anti-clockwise using a 6 mm Allen key. Torque tighten the tensioning roller bolt ( 27 ± 2.7 Nm ) .

Note: There must be 19 belt grooves between the marks of the high-pressure pump and camshaft pulleys.

Refit the accessories crankshaft pulley with a new bolt. Torque and angle tighten (crankshaft pressed against the TDC setting pin): - the crankshaft accessories pulley M12 mounting bolt ( 60 ± 6 Nm + 100˚ ± 10˚ ) , - the crankshaft accessories pulley M14 mounting bolt ( 120 ± 12 Nm + 95˚ ± 15˚ ) , Remove the following tools: - the camshaft pulley timing pin (Mot. 1430) , - the TDC setting pin (Mot. 1489) ,

10A-287

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790

11

12 10

9

19702

Rotate the crankshaft twice in a clockwise direction (timing end) before the camshaft pulley hole (9) is opposite the cylinder head hole (10) . Screw the TDC setting pin (Mot. 1489) into the cylinder block. Bring the crankshaft slowly and smoothly against the TDC setting pin.

19655

Set the camshaft pulley using the (Mot. 1430) .

Note: There must be 19 belt grooves between the marks of the camshaft pulley (11) and the highpressure pump pulley (12) . Remove: - the TDC setting pin (Mot. 1489) , - the Set of 5 timing pins for the camshaft and crankshaft pulleys (Mot. 1430) .

Note: After two turns, the tensioning roller index markers may be in two different positions. The rotation of the tensioning roller eccentric depends on the position.

10A-288

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790 Second position

First position

111083

111081

Loosen the tensioning roller bolt by no more than one turn, holding it with a 6 mm Allen key. Gradually align the adjustable index marker (21) to the middle of the timing window, (22) turning the key anti-clockwise.

111082

111081

Loosen the tensioning roller bolt by no more than one turn, holding it with a 6 mm Allen key. Gradually align the adjustable index marker (23) to the middle of the timing window, (24) turning the key clockwise. Torque tighten the tensioning roller bolt ( 27 ± 2.7 Nm ) . Rotate the crankshaft clockwise through two revolutions (timing end), before the camshaft pulley hole is opposite the cylinder head hole.

10A-289

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790 Screw the TDC setting pin (Mot. 1489) into the cylinder block. Bring the crankshaft slowly and smoothly against the TDC setting pin.

19657

Set the camshaft pulley using the (Mot. 1430) . If this is not possible, repeat the timing belt refitting operation. Remove the following tools: - TDC setting pin (Mot. 1489) , - set of 5 timing pins for the camshaft and crankshaft pulleys (Mot. 1430) . Place a drop of ADHESIVE SILICONE SEALANT on the threading of the TDC pin plug. Tighten to torque the TDC pin plug cap ( 20 ± 2 Nm ).

10A-290

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790

19654-2

Refit the cylinder head suspended mounting. Tighten to torque the cylinder head suspended mounting bolts ( 21 ± 2.1 Nm ) .

10A-291

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790

19654-1

15

16

19659

Refit the timing cover, positioning tab (15) in lower timing cover opening. (16) .

10A-292

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790

19654

Refit the high-pressure pump position sensor. Tighten to torque the high-pressure pump position sensor bolt ( 8 ± 0.8 Nm ) . Refit the upper timing cover.

10A-293

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 732 or 764 Tightening torquesm

Special tooling required Mot. 1430

Set of 5 crankshaft and camshaft pulley timing pins.

Mot. 1489

TDC pin plug

20 ± 2 Nm

cylinder head suspended mounting bolts

21 ± 2.1 Nm

cylinder head suspended mounting bolts

21 ± 2.1 Nm

TDC locating pin.

Tightening torquesm cylinder head mounting bolts

25 ± 2.5 Nm

cylinder head mounting bolts

255˚ ± 10˚

rocker cover mounting bolts

12 ± 1.2 Nm

dipstick guide mounting nuts

10 ± 1 Nm

damper valve mounting nuts

12 ± 1.2 Nm

turbocharger oil return pipe mounting bolts

12 ± 1.2 Nm

the nuts mounting the catalytic converter on the turbocharger

26 ± 2.6 Nm

the bolts mounting the catalytic converter stay on the engine

44 ± 4.4 Nm

the bolts mounting the catalytic converter stay on the catalytic converter

26 ± 2.6 Nm

inner timing mounting bolts

cover

I - RECOMMENDATIONS FOR REPAIRING THE CYLINDER HEAD

IMPORTANT Wear protective gloves during every operation.

WARNING When handling the cylinder head gasket, use the cylinder barrel to hold it. The sealing surfaces must be clean, dry and free from grease (avoid finger marks). Applying excess sealant could cause it to be squeezed out when parts are tightened. A mixture of sealant and fluid could damage certain components (engine, radiator, etc.) To obtain correct tightening of the cylinder head bolts, remove any oil from the cylinder head mounting holes using a syringe. Do not retighten the cylinder head bolts after applying this procedure. Do not lubricate the new cylinder head bolts.

II - PARTS AND CONSUMABLES FOR THE REPAIR 9 ± 0.9 Nm

Parts always to be replaced for the cylinder head

tensioning roller bolt

27 ± 2.7 Nm

- The cylinder head gasket,

the camshaft pulley wheel bolts

14 ± 1.4 Nm

- The cylinder head bolts,

the tensioning roller bolt

27 ± 2.7 Nm

the camshaft pulley wheel bolts

± 1.4 Nm 14±

the crankshaft accessories pulley M14 bolt

120 ± 12 Nm + 95˚ ± 15˚

- The rocker cover gasket, - The damper valve seal, - The seals on the turbocharger oil return pipe, - The catalytic converter seal. Consumables - Degreaser, part no. 77 11 224 559 , - Silicone adhesive sealant, part no. 77 11 227 484 .

10A-294

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 732 or 764 III - EQUIPMENT REQUIRED FOR THE CYLINDER HEAD

Degrease the rocker cover sealing surface on the cylinder head. Fit a new seal onto the rocker cover.

- Torque/angle wrench, - Torque wrench - Cylinder head bolt tightening gauge (angular measuring type), - Female torx socket ( 14 ), - Protective gloves. IV - REFITTING OF THE CYLINDER HEAD Position the pistons at mid-stroke. Apply degreaser to the: 113477

- the combustion side of the cylinder head,

Apply four beads (11) of SILICONE ADHESIVE SEALANT ( 2 mm in diameter).

- the combustion face of the cylinder block. Check for the cylinder head centring dowels on the cylinder block. Refit the cylinder head gasket (positioning the TOP facing upwards) onto the cylinder block.

Refit: - the rocker cover, - the rocker cover mounting bolts.

Remove the cylinder head from the cylinder head support. Refit: - the cylinder head, - the new cylinder head mounting bolts.

113476 113478

Tighten to torque and in order the cylinder head mounting bolts ( 25 ± 2.5 Nm ) . Check that all the cylinder head mounting bolts are tightened to (25 ± 2.5 Nm) . Angle tighten in order the cylinder head mounting bolts ( 255˚ ± 10˚ ) .

10A-295

Tighten to torque and in order the rocker cover mounting bolts ( 12 ± 1.2 Nm ) .

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 732 or 764

113475

113479

Refit:

Refit:

- the turbocharger oil return pipe,

- the dipstick guide,

- the turbocharger oil return pipe mounting bolts. - the dipstick guide mounting nuts (15) . Tighten to torque the dipstick guide mounting nuts ( 10 ± 1 Nm ) . Refit a new seal to the damper valve. Refit: - the damper valve, - the damper valve mounting nuts (13) . Tighten to torque the damper valve mounting nuts ( 12 ± 1.2 Nm ) . Refit: - the damper valve mounting bracket, - the mounting bolts securing the damper valve mounting bracket, - the exhaust gas recirculation valve retaining bracket, - the exhaust gas recirculation valve retaining bracket mounting bolts. Fit the new seals onto the turbocharger oil return pipe. Use engine oil to lubricate the turbocharger oil return pipe O-ring seals.

10A-296

Tighten to torque the turbocharger oil return pipe mounting bolts ( 12 ± 1.2 Nm ) . Fit a new seal between the turbocharger and the catalytic converter.

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 732 or 764

113474

113473

Refit:

Refit:

- the catalytic converter,

- the inner timing cover (tilting the alternator if necessary),

- the nuts mounting the catalytic converter on the turbocharger,

- the inner timing cover mounting bolts.

- the catalytic converter mounting stay,

Tighten to torque the inner timing cover mounting bolts ( 9 ± 0.9 Nm ) .

- the catalytic converter stay mounting bolts. Tighten to torque: - the nuts mounting the catalytic converter on the turbocharger ( 26 ± 2.6 Nm ) (16) ,

V - RECOMMENDATIONS FOR REPAIRING THE TIMING

- the bolts mounting the catalytic converter stay on the engine ( 44 ± 4.4 Nm ) (17) ,

IMPORTANT Wear protective gloves during every operation.

- the bolts mounting the catalytic converter stay on the catalytic converter ( 26 ± 2.6 Nm ) (18) .

WARNING The belt must be replaced with a new one if it has been removed. Never turn the engine in the opposite direction to its normal operating direction. Do not run the engine without the accessories belt so as not to damage the crankshaft accessories pulley. When replacing the belt, always replace the tensioning rollers and fixed rollers. VI - PARTS AND CONSUMABLES Parts always to be replaced for the timing - Timing belt,

10A-297

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 732 or 764 - Timing belt tensioning roller, - Crankshaft accessories pulley bolt. Consumables - Silicone adhesive sealant, part no. 77 11 227 484 VII - EQUIPMENT REQUIRED FOR THE TIMING BELT

- Protective gloves, - Allen key ( 6 mm ), - Female torx socket ( 14 ), - Offset wrench ( 18 mm ), - Torque/angle wrench, - Torque wrench - Cylinder head bolt tightening gauge (angular measuring type).

109042

VIII - REFITTING THE TIMING BELT Refit the crankshaft timing sprocket.

109043

Refit the timing tensioning roller. Put the tensioning roller spigot (1) in the cylinder head groove (2) . Engage the pin (1) (Mot. 1430) in the holes of the camshaft pulley and cylinder head, turning the camshaft using an 18 mm offset wrench if necessary. Check that the high-pressure pump mark (3) has shifted one tooth to the right of the vertical axle (4) .

10A-298

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting K9K, and 732 or 764

14489

Position the crankshaft so that it presses on the TDC setting pin (Mot. 1489) (the crankshaft timing sprocket cotter (5) must face upwards)

109042

Remove one bolt from the camshaft pulley wheel. Loosen the two other camshaft pulley wheel bolts (6) by one turn.

10A-299

10A

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 732 or 764

109044

Fit the timing belt, starting with the crankshaft sprocket, by aligning the marks on the belt with those on the crankshaft sprockets, the camshaft and the highpressure pump. note: There should be 19 tooth belt grooves on the belt between the camshaft sprocket marks and the high-pressure pump, and 51 tooth belt grooves between the crankshaft sprockets and the highpressure pump.

10A-300

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting K9K, and 732 or 764

19658

Position the tensioning roller adjustable index (7) opposite the spigot, turning the eccentric cam anticlockwise using a 6 mm Allen key. Tighten to torque the tensioning roller bolt ( 27 ± 2.7 Nm ) .

109047

Check that the camshaft pulley hub bolts are not fully up against the camshaft pulley wheel.

10A-301

10A

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 732 or 764

109045

Refit the bolt to the camshaft pulley wheel. Tighten to torque the camshaft pulley wheel bolts ( 14 ± 1.4 Nm ) . Remove: - the TDC setting pin (Mot. 1489) , - the set of 5 timing pins for the camshaft and crankshaft pulleys (Mot. 1430) .

107272

Tighten the old crankshaft accessories pulley bolt fitted with a spacer (which does not cover the timing sprocket mark) (8) onto the crankshaft.

10A-302

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 732 or 764

107270

Rotate the crankshaft clockwise through two revolutions (timing end), before the camshaft pulley hole (9) is opposite the cylinder head hole (10) . Screw the TDC setting pin (Mot. 1489) into the cylinder block. Bring the crankshaft slowly and smoothly against the TDC setting pin.

109049

Set the camshaft pulley using the (Mot. 1430) .

10A-303

109048

If the pin (Mot. 1430) does not engage: loosen the camshaft pulley wheel bolts by one turn, Turn the camshaft pulley hub using an 18 mm offset wrench to set the camshaft pulley hub timing. Do not retighten the camshaft pulley wheel bolts.

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 732 or 764

109045

Check that the crankshaft timing sprocket cotter (16) is positioned vertically at the top.

note: After two turns, the tensioning roller index markers may be in two different positions. The rotation of the tensioning roller eccentric depends on the position.

10A-304

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 732 or 764

111083

111082

111081

111081

Loosen the tensioning roller bolt by no more than one turn, holding it with a 6 mm Allen key.

Loosen the tensioning roller bolt by no more than one turn, holding it with a 6 mm Allen key.

Gradually align the adjustable index (21) in the middle of the timing window (22) , turning the key anticlockwise.

Gradually align the adjustable index (23) in the middle of the timing window (24) , turning the key clockwise. Tighten to torque: - the tensioning roller bolt ( 27 ± 2.7 Nm ) , ± 1.4 Nm ) . - the camshaft pulley wheel bolts ( 14± Remove the following tools: - TDC setting pin (Mot. 1489) ,

10A-305

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 732 or 764 - the set of 5 timing pins for the camshaft and crankshaft pulleys (Mot. 1430) . Rotate the crankshaft clockwise through two revolutions (timing end), before the camshaft pulley hole is opposite the cylinder head hole. Screw the TDC setting pin (Mot. 1489) into the cylinder block. Bring the crankshaft slowly and smoothly against the TDC setting pin.

107260

Refit the accessories crankshaft pulley with a new bolt. Tighten to torque and angle (crankshaft in contact with the TDC setting pin) the crankshaft accessories pulley M14 bolt ( 120 ± 12 Nm + 95˚ ± 15˚ ) . Remove the following tools: - TDC setting pin (Mot. 1489) , 109049

Set the camshaft pulley using the (Mot. 1430) . If this is not possible, repeat the timing belt refitting operation.

10A-306

- the set of 5 timing pins for the camshaft and crankshaft pulleys (Mot. 1430) . Refit the TDC pin plug, coating the thread with SILICONE ADHESIVE SEALANT . Tighten to torque the TDC pin plug ( 20 ± 2 Nm ) .

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting K9K, and 732 or 764

K9K, and 732

112989

Refit the cylinder head suspended mounting. Tighten to torque the cylinder head suspended mounting bolts ( 21 ± 2.1 Nm ) .

10A-307

10A

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 732 or 764

19654-1

19659

112990

Refit the upper timing cover.

Refit: - the lower timing cover, positioning the tab (19) in the inner timing cover hole (20) , - the timing cover plastic bolt (25) .

10A-308

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 732 or 764

K9K, and 764

111741

111742

Refit the cylinder head suspended mounting. Tighten to torque the cylinder head suspended mounting bolts ( 21 ± 2.1 Nm ) .

19659

Refit: - the timing cover, positioning the tab (27) in the inner timing cover hole (28) , - the timing cover plastic bolt (26) .

10A-309

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768 Special tooling required

Tightening torquesm

Mot. 1430

Set of 5 crankshaft and camshaft pulley timing pins.

Mot. 1489

TDC locating pin.

cylinder head suspended mounting bolts

21 ± 2.1 Nm

high-pressure pump position sensor bolt

8 Nm

I - RECOMMENDATIONS FOR REPAIRING THE CYLINDER HEAD

Tightening torquesm cylinder head mounting bolts

25 ± 2.5 Nm

cylinder head mounting bolts

255˚ ± 10˚

rocker cover mounting bolts

12 ± 1.2 Nm

turbocharger oil return pipe mounting bolts

12 ± 1.2 Nm

When handling the cylinder head gasket, use the cylinder barrel to hold it.

the nuts mounting the catalytic converter on the turbocharger

26 ± 2.6 Nm

The sealing surfaces must be clean, dry and free from grease (avoid finger marks).

the bolts mounting the catalytic converter stay on the engine

44 ± 4.4 Nm

Applying excess sealant could cause it to be squeezed out when parts are tightened. A mixture of sealant and fluid could damage certain components (engine, radiator, etc.)

the bolts mounting the catalytic converter stay on the catalytic converter

26 ± 2.6 Nm

To obtain correct tightening of the cylinder head bolts, remove any oil from the cylinder head mounting holes using a syringe.

oil vapour recirculation valve mounting nuts

12 ± 1.2 Nm

inner timing mounting bolts

cover

tensioning roller bolt

Wear protective gloves during every operation.

WARNING

Do not retighten the cylinder head bolts after applying this procedure.

9 ± 0.9 Nm

Do not lubricate the new cylinder head bolts.

II - PARTS AND CONSUMABLES FOR THE REPAIR

27 ± 2.7 N.m

the camshaft pulley wheel bolts

14 ± 1.4 Nm

the tensioning roller bolt

27 ± 2.7 Nm

the camshaft pulley wheel bolts

± 1.4 Nm 14±

the crankshaft accessories pulley M14 bolt

120 ± 12 Nm + 95˚ ± 15˚

TDC pin plug

IMPORTANT

Parts always to be replaced for the cylinder head - The cylinder head gasket, - The cylinder head bolts, - The rocker cover gasket, - The oil vapour recirculation valve seal, - The seals on the turbocharger oil return pipe,

20 ± 2 Nm

- The catalytic converter seal. Consumables - Degreaser, part no. 77 11 224 559 , - Silicone adhesive sealant, part no. 77 11 227 484 .

10A-310

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768 III - EQUIPMENT REQUIRED FOR THE CYLINDER HEAD

Degrease the rocker cover sealing surface on the cylinder head. Refit a new seal onto the rocker cover.

- Torque/angle wrench, - Torque wrench - Cylinder head bolt tightening gauge (angular measuring type), - Female torx socket ( 14 ), - Protective gloves. IV - REFITTING OF THE CYLINDER HEAD Position the pistons at mid-stroke. Apply degreaser to: - the combustion side of the cylinder head,

19712-1

- the combustion face of the cylinder block.

Apply four beads (11) of SILICONE ADHESIVE SEALANT ( 2 mms in diameter).

Check for the cylinder head centring dowels on the cylinder block.

Refit:

Refit the cylinder head gasket (positioning the TOP facing upwards) onto the cylinder block.

- the rocker cover, - the rocker cover mounting bolts.

Remove the cylinder head from the cylinder head support. Refit: - the cylinder head, - the new cylinder head mounting bolts.

19711 19712

Tighten to torque and in order the cylinder head mounting bolts ( 25 ± 2.5 Nm ) . Check that all the cylinder head mounting bolts are tightened to (25 ± 2.5 Nm) . Angle tighten in order the cylinder head mounting bolts ( 255˚ ± 10˚ ) .

10A-311

Tighten to torque and in order the rocker cover mounting bolts ( 12 ± 1.2 Nm ) . Refit the dipstick guide tube. Clip the fuel return pipe onto the rocker cover. Fit the new seals onto the turbocharger oil return pipe.

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768 Use engine oil to lubricate the turbocharger oil return pipe O-ring seals.

112328

Refit: 112327

- the catalytic converter,

Refit:

- the nuts mounting the catalytic converter on the turbocharger,

- the turbocharger oil return pipe, - the turbocharger oil return pipe mounting bolts.

- the catalytic converter mounting stay,

Tighten to torque the turbocharger oil return pipe mounting bolts ( 12 ± 1.2 Nm ) . Fit a new seal between the turbocharger and the catalytic converter.

- the catalytic converter stay mounting bolts. Tighten to torque: - the nuts mounting the catalytic converter on the turbocharger ( 26 ± 2.6 Nm ) (12) , - the bolts mounting the catalytic converter stay on the engine ( 44 ± 4.4 Nm ) (13) , - the bolts mounting the catalytic converter stay on the catalytic converter ( 26 ± 2.6 Nm ) (14) .

10A-312

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

112325

19710

Fit a new seal onto the oil vapour recirculation valve.

Refit:

Refit:

- the inner timing cover (tilting the alternator if necessary),

- the oil vapour recirculation valve,

- the inner timing cover mounting bolts.

- the oil vapour recirculation valve mounting nuts (16) .

Tighten to torque the inner timing cover mounting bolts ( 9 ± 0.9 Nm ) .

Tighten to torque the oil vapour recirculation valve mounting nuts ( 12 ± 1.2 Nm ) .

V - RECOMMENDATIONS FOR REPAIRING THE TIMING BELT

Connect the oil vapour recirculation pipe (15) . Refit: - the oil vapour recirculation valve retaining bracket, - the mounting bolts of the oil vapour recirculation valve retaining bracket.

IMPORTANT Wear protective gloves during every operation.

WARNING The belt must be replaced with a new one if it has been removed. Never turn the engine in the opposite direction to its normal operating direction. Do not run the engine without the accessories belt so as not to damage the crankshaft accessories pulley. When replacing the belt, always replace the tensioning rollers and fixed rollers.

10A-313

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768 - Allen key ( 6 mm ),

VI - PARTS AND CONSUMABLES FOR THE REPAIR

- Female torx socket ( 14 ),

Pièces à remplacer systématiquement pour la distribution

- Offset wrench ( 18 mm ), - Torque/angle wrench,

- Timing belt,

- Torque wrench

- Timing belt tensioning roller,

- Cylinder head bolt tightening gauge (angular measuring type).

- Crankshaft accessories pulley bolt. Ingrédients - Silicone adhesive sealant, part no. 77 11 227 484

VIII - REFITTING THE TIMING Refit the crankshaft timing sprocket.

VII - EQUIPMENT REQUIRED FOR THE TIMING BELT

- Protective gloves,

107263

Refit the timing tensioning roller. Put the tensioning roller spigot (1) in the cylinder head groove (2) . Engage the pin (1) (Mot. 1430) in the holes of the camshaft pulley and cylinder head, turning the camshaft using an 18 mm offset wrench if necessary.

10A-314

Check that the mark on the high-pressure pump (3) is opposite the bolt head (4) .

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

14489

Position the crankshaft so that it presses against the TDC setting pin (Mot. 1489) (the crankshaft sprocket cotter (5) must face upwards).

107264

Remove one bolt from the camshaft pulley wheel.

Loosen the two other camshaft pulley wheel bolts (6) by one turn.

10A-315

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

107265

Fit the timing belt, starting with the crankshaft sprocket, by aligning the marks on the belt with those on the crankshaft sprockets, the camshaft and the highpressure pump. note: There should be 19 tooth belt grooves between the camshaft sprocket marks and the high-pressure pump, and 51 tooth valleys between the crankshaft sprockets and the high-pressure pump.

10A-316

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

19658

Position the tensioning roller adjustable index (7) opposite the spigot, turning the eccentric cam anticlockwise using a 6 mm Allen key. Tighten to torque the tensioning roller bolt ( 27 ± 2.7 N.m ) .

107268

Check that the camshaft pulley hub bolts are not fully up against the camshaft pulley wheel.

10A-317

10A

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

107266

Refit the bolt to the camshaft pulley wheel. Tighten to torque the camshaft pulley wheel bolts ( 14 ± 1.4 Nm ) . Remove: - the TDC setting pin (Mot. 1489) , - the set of 5 timing pins for the camshaft and crankshaft pulleys (Mot. 1430) .

107272

Tighten the old crankshaft accessories pulley bolt fitted with a spacer (which does not cover the timing sprocket mark) (8) onto the crankshaft.

10A-318

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

107270

Rotate the crankshaft clockwise through two revolutions (timing end), before the camshaft pulley hole (9) is opposite the cylinder head hole (10) . Screw the TDC setting pin (Mot. 1489) into the cylinder block. Bring the crankshaft slowly and smoothly against the TDC setting pin.

107271

Set the camshaft pulley using the (Mot. 1430) .

10A-319

107269

If the pin (Mot. 1430) does not engage: loosen the camshaft pulley wheel bolts by one turn at most, Turn the camshaft pulley hub using an 18 mm offset wrench to set the camshaft pulley hub timing. Do not retighten the camshaft pulley wheel bolts.

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

107267

Check: - that the high-pressure pump sprocket mark (14) is opposite the bolt head (13) , - that the crankshaft timing sprocket cotter (16) is positioned vertically at the top, - that there are 19 tooth belt grooves between the camshaft sprocket marks (11) and the high-pressure pump sprocket (12) , - that there are 51 tooth belt grooves between the crankshaft sprocket marks (15) and the high-pressure pump sprocket (12) .

note: After two turns, the tensioning roller index markers may be in two different positions. The rotation of the tensioning roller eccentric cam depends on the position.

10A-320

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

111083

111082

111081

111081

Loosen the tensioning roller bolt by no more than one turn, holding it with a 6 mm Allen key.

Loosen the tensioning roller bolt by no more than one turn, holding it with a 6 mm Allen key.

Gradually align the adjustable index (21) in the middle of the timing window (22) , turning the key anticlockwise.

Gradually align the adjustable index (23) in the middle of the timing window (24) , turning the key clockwise. Tighten to torque: - the tensioning roller bolt ( 27 ± 2.7 Nm ) , ± 1.4 Nm ) . - the camshaft pulley wheel bolts ( 14± Remove the following tools: - TDC setting pin, (Mot. 1489)

10A-321

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768 - the set of 5 timing pins for the camshaft and crankshaft pulleys (Mot. 1430) . Rotate the crankshaft clockwise through two revolutions (timing end), before the camshaft pulley hole is opposite the cylinder head hole. Screw the TDC setting pin (Mot. 1489) into the cylinder block. Bring the crankshaft slowly and smoothly into contact with the TDC setting pin.

107260

Refit the accessories crankshaft pulley with a new bolt. Tighten to torque and angle (crankshaft in contact with the TDC setting pin) the crankshaft accessories pulley M14 bolt ( 120 ± 12 Nm + 95˚ ± 15˚ ) . Remove the following tools: - TDC setting pin, (Mot. 1489) 107271

Set the camshaft pulley using the (Mot. 1430) . If this is not possible, repeat the timing belt refitting operation.

10A-322

- the set of 5 timing pins for the camshaft and crankshaft pulleys (Mot. 1430) . Refit the TDC pin plug, coating the thread with SILICONE ADHESIVE SEALANT . Tighten to torque the TDC pin plug ( 20 ± 2 Nm ) .

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

107261

Refit the cylinder head suspended mounting. Tighten to torque the cylinder head suspended mounting bolts ( 21 ± 2.1 Nm ) .

10A-323

10A

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

19654-1

19659

Refit: - the lower timing cover, positioning the tab (19) in the inner timing cover hole (20) , - the timing cover plastic mounting bolt.

10A-324

ENGINE AND LOWER ENGINE ASSEMBLY Timing - cylinder head: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

19654

Refit the high-pressure pump position sensor. Tighten to torque the high-pressure pump position sensor bolt ( 8 Nm ) . Refit the upper timing cover.

10A-325

ENGINE AND LOWER ENGINE ASSEMBLY Accessories belt: Refitting

10A

Special tooling required Mot. 1638

Accessories belt tension tool. For engines fitted with a mechanical tensioning roller.

Mot. 1505

Belt tension setting tool (frequency meter)

Mot. 1715

Belt tension checking tool (frequency indicator).

Tightening torquesm mechanical tensioning roller mounting bolts

35 ± 3.5 Nm

auto tensioner mounting bolt

40 ± 4 Nm

106000

I - RECOMMENDATIONS FOR REPAIR

WARNING Certain accessories belts have five teeth whereas the air conditioning compressor pulley, power-assisted steering pump pulley, and alternator pulley all have six teeth. In this case, it is essential to check that the inner tooth (1) of the pulleys remains free when fitting the accessories belt.

IMPORTANT Wear protective gloves during every operation.

Never turn the engine in the opposite direction to its normal operating direction. Use a brush to remove any deposits from the crankshaft accessories pulley V grooves. For engines fitted with a mechanical tensioning roller, it is essential to replace the tensioning roller mounting bolts.

II - PARTS AND CONSUMABLES FOR THE REPAIR Parts always to be replaced - The mechanical or automatic tensioning roller, - The mechanical tensioning roller mounting bolts with M8 bolts - 125 X 20 , part no. 77 03 002 059 , - The accessories belt. III - EQUIPMENT REQUIRED

- Brush, - Torque wrench

10A-326

ENGINE AND LOWER ENGINE ASSEMBLY Accessories belt: Refitting

10A

- Protective gloves, - Tubular hexagon box spanner ( 16 mm ), - Offset wrench ( 16 mm ). IV - REFITTING 1 - Engine without air conditioning Use a brush to remove any deposits from the crankshaft accessories pulley V grooves. Refit: - the tensioning roller, - the new tensioning roller mounting bolts.

21861

Fit the (Mot. 1638) into the tensioning roller notch (as indicated in the diagram). Tension the accessories belt using the (Mot. 1638) by tightening nut (3) . Check the accessories belt tension at (4) using the (Mot. 1505) or (Mot. 1715) . The accessories belt tension must be between 223 and 245 Hz .

20845

It is essential to turn the engine through two revolutions to position the accessories belt correctly.

It is essential to leave one inner tooth (2) of the pulleys free for engines fitted with a belt with five teeth for pulleys with six teeth.

Check that the accessories belt tension is between 223 and 245 Hz at measuring point (4) .

Refit the accessories belt.

Adjust the accessories belt tension if necessary.

Check that the two mechanical tensioning roller bolts are not overtightened.

Tighten to torque the mechanical tensioning roller mounting bolts ( 35 ± 3.5 Nm ) . 2 - Engine with air conditioning Use a brush to remove any deposits from the crankshaft accessories pulley V grooves.

10A-327

ENGINE AND LOWER ENGINE ASSEMBLY Accessories belt: Refitting

10A

19703

Refit:

19651

Turn the accessories belt auto tensioner clockwise using a 16 mm spanner.

- the auto tensioner,

Refit the crankshaft accessories belt.

- the auto tensioner mounting bolt (5) . Tighten to torque the auto tensioner mounting bolt ( 40 ± 4 Nm ) .

106000

It is essential to leave one inner tooth (6) of the pulleys free for engines fitted with a belt with five teeth for pulleys with six teeth.

10A-328

Rotate the crankshaft twice to position the accessories belt correctly.

ENGINE AND LOWER ENGINE ASSEMBLY Engine: Refitting

10A

Tightening torquesm

Special tooling required Mot. 792-03

Engine support plate for Desvil engine stand

the flywheel mounting bolts

55 ± 5.5 Nm

Mot. 1638

Accessories belt tension tool. For engines fitted with a mechanical tensioning roller.

the dual-mass flywheel mounting bolts

20 ± 2 Nm + 36˚ ± 6˚

clutch pressure plate mounting bolts

M6 bolts to 14 ± 1.4 Nm and M7 bolt to 20 ± 2 Nm

Mot. 1505

Belt tension setting tool (frequency meter)

Mot. 1715

Belt tension checking tool (frequency indicator).

Mot. 1723

I - RECOMMENDATIONS FOR REPAIR

Engine support for DESVIL engine support stand.

Mot. 582-01

Flywheel locking tool.

Mot. 1677

Flywheel locking tool.

Emb. 1780

Set of clutch disc centring mandrels.

Tightening torquesm coolant pump inlet pipe mounting bolt

22 ± 2.2 Nm

multifunction support mounting bolts (1 to 6 or 1 to 5)

44 ± 4.4 Nm

multifunction support mounting bolt (7)

21 ± 2.1 Nm

the power-assisted steeri n g pump or dummy pulley mounting bolts

21 ± 2.1 Nm

the air conditioning compressor mounting bolts

21 ± 2.1 Nm

the alternator mounting bolts

21 ± 2.1 Nm

mechanical tensioning roller mounting bolts

35 ± 3.5 Nm

auto tensioner mounting bolt

40 ± 4 Nm

10A-329

IMPORTANT Wear protective gloves throughout the operation.

ENGINE AND LOWER ENGINE ASSEMBLY Engine: Refitting

10A

III - ESSENTIAL EQUIPMENT

- Workshop crane, - Load positioner, - Brush, - Offset wrench or tubular hexagon box spanner 16 mm , - Protective gloves, - Male torx socket, - Torque/angle wrench, - Torque wrench - Cylinder head bolt tightening gauge (angular measuring type).

106000

WARNING Certain accessories belts have five teeth whereas the air conditioning compressor pulley, power-assisted steering pump pulley, and alternator pulley all have six teeth. In this case, it is essential to check that the inner tooth (3) of the pulleys remains free when fitting the accessories belt.

IV - REBUILDING THE ENGINE FOR ENGINES ATTACHED ON SIDE OF OIL FILTER 1 - This fitting operation only concerns K9K 260270-272-700-702-704-706-710-722-750-752-790 engines. Fit a load positioner onto the engine lifting eyes. Remove the engine from the engine stand using a workshop hoist. Remove the support plate (Mot. 792-03) from the engine.

Never turn the engine in the opposite direction to its normal operating direction. Use a brush to remove any deposits from the crankshaft accessories pulley V grooves.

X

Y

For engines fitted with a mechanical tensioning roller, it is essential to replace the tensioning roller mounting bolts.

II - PARTS AND CONSUMABLES FOR THE REPAIR Parts always to be replaced - Coolant pump inlet pipe seal, - Flywheel mounting bolt, - Accessories belt mechanical or auto tensioner, - Mechanical tensioning roller mounting bolts with M8 - 125 X20 bolts, part no. 77 03 002 059

A 19705

- Accessories belt. Consumables

Remove support studs (A) , (X) and (Y) from the cylinder block.

- Degreaser, part no. 77 11 224 559 .

Refit a new O-ring onto the coolant pump inlet pipe.

10A-330

ENGINE AND LOWER ENGINE ASSEMBLY Engine: Refitting

10A

Apply a small amount of soapy water to the coolant pump inlet pipe O-ring.

19704 19706

Refit: - the coolant pump inlet pipe, - the coolant pump inlet pipe mounting bolt. Tighten to torque the coolant pump inlet pipe mounting bolt ( 22 ± 2.2 Nm ) . Connect the hoses to the coolant pump inlet pipe.

111057

Refit: - the multifunction support, - the multifunction support mounting bolts. Tighten to torque and in order the multifunction support mounting bolts (1 to 6 or 1 to 5) ( 44 ± 4.4 Nm ) Tighten to torque the multifunction support mounting bolt (7) ( 21 ± 2.1 Nm ) .

10A-331

ENGINE AND LOWER ENGINE ASSEMBLY Engine: Refitting

10A

- the power-assisted steering pump or dummy pulley mounting bolts ( 21 ± 2.1 Nm ) , - the air conditioning compressor mounting bolts ( 21 ± 2.1 Nm ) , - the alternator mounting bolts ( 21 ± 2.1 Nm ) . 2 - Refitting the accessories belt for engines without air conditioning Use a brush to remove any deposits from the crankshaft accessories pulley V grooves. Refit: - the tensioning roller, - the new tensioning roller mounting bolts.

107853

20845

It is essential to leave one inner tooth (11) of the pulleys free for engines fitted with a belt with five teeth for pulleys with six teeth. Refit the accessories belt. Check that the two mechanical tensioning roller bolts are not overtightened.

111079

Refit: - the power-assisted steering pump or dummy pulley, - the power-assisted steering pump or dummy pulley mounting bolts (10) , - the air conditioning compressor (if fitted to the vehicle), - the air conditioning compressor mounting bolts (9) , - the alternator, - the alternator mounting bolts (8) . Tighten to torque:

10A-332

ENGINE AND LOWER ENGINE ASSEMBLY Engine: Refitting

10A

21861

Fit the (Mot. 1638) into the tensioning roller notch (as indicated in the diagram). Put the accessories belt under tension using the (Mot. 1638) by tightening nut (12) . Check the accessories belt tension at (13) using the (Mot. 1505) or (Mot. 1715) .

19703

Refit: - the auto tensioner, - the auto tensioner mounting bolt (14) . Tighten to torque the auto tensioner mounting bolt ( 40 ± 4 Nm ) .

The accessories belt tension must be between 223 to 245 Hz . It is essential to turn the engine through two revolutions to position the accessories belt correctly. Check that the accessories belt tension is between 223 and 245 Hz at measuring point (13) . Adjust the accessories belt tension if necessary. Tighten to torque the mechanical tensioning roller mounting bolts ( 35 ± 3.5 Nm ) . 3 - Refitting the accessories belt for engines with air conditioning Use a brush to remove any deposits from the crankshaft accessories pulley V grooves.

106000

It is essential to leave one inner tooth (15) of the pulleys free for engines fitted with a belt with five teeth for pulleys with six teeth.

10A-333

ENGINE AND LOWER ENGINE ASSEMBLY Engine: Refitting

19651

10A

101356

Turn the accessories belt auto tensioner clockwise using a 16 mm spanner. Note:

Refit the crankshaft accessories belt. Rotate the crankshaft twice to position the accessories belt correctly.

Certain flywheels have a shim (1 ) . It is essential to position the shim chamfer (1 6) on the flywheel end .

V - REBUILDING THE ENGINE ATTACHED TO THE FLYWHEEL END This fitting operation concerns all K9K engines Fit a load positioner onto the engine lifting eyes. Remove the engine from the engine stand using a workshop hoist. Remove: - the engine from the support plate (Mot. 1723) , - the studs from the cylinder block.

Note: For engines which have a starter located on the exhaust side, the flywheel must only be refitted after the engine has been removed from the engine stand. 20172

Refit: - the flywheel, - the new flywheel mounting bolts, - the engine flywheel locking tool (Mot. 582-01) or (Mot. 1677) .

10A-334

ENGINE AND LOWER ENGINE ASSEMBLY Engine: Refitting Tighten to torque and in order: - the flywheel mounting bolts ( 55 ± 5.5 Nm ) , - the dual-mass flywheel mounting bolts ( 20 ± 2 Nm + 36˚ ± 6˚ ) . Degrease the flywheel friction surface using degreaser. Refit the friction plate (orientating it correctly). Centre the friction plate using the (Emb. 1780) . Degrease the clutch pressure plate friction surface using degreaser.

103285

Refit: - the clutch pressure plate, - the clutch pressure plate mounting bolts. Gradually tighten the clutch pressure plate mounting bolts. Tighten to torque the clutch pressure plate mounting bolts ( M6 bolts to 14 ± 1.4 Nm and M7 bolt to 20 ± 2 Nm ) . Remove the engine flywheel locking tool (Mot. 58201) or (Mot. 1677) .

10A-335

10A

ENGINE AND LOWER ENGINE ASSEMBLY Timing belt: Removal

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768 II - ESSENTIAL EQUIPMENT

Special tooling required Mot. 1489

TDC locating pin.

Mot. 1430

Set of 5 crankshaft and camshaft pulley timing pins.

- Protective gloves, - Large screwdriver, - Allen key ( 6 mm ), - Torx socket ( 14 ).

I - RECOMMENDATIONS FOR REPAIR III - REMOVAL IMPORTANT Wear protective gloves during every operation.

WARNING Never turn the engine in the opposite direction to its normal operating direction.

Do not run the engine without the accessories belt so as not to damage the crankshaft accessories pulley.

19654

Remove the upper timing cover by unclipping both tabs (1) .

10A-336

ENGINE AND LOWER ENGINE ASSEMBLY Timing belt: Removal

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

19654-1

Remove: - the high-pressure pump position sensor (2) , - the plastic bolt (4) . Unclip the three tabs (3) . Remove the lower timing cover.

107261

Remove the cylinder head suspended mounting.

10A-337

ENGINE AND LOWER ENGINE ASSEMBLY Timing belt: Removal

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

19650

Remove the TDC setting pin plug using a female torx socket ( 14 ).

19650-1

Screw in the TDC setting pin (1) (Mot. 1489) .

14489 107270

Turn the crankshaft to position the camshaft pulley hole (5) almost opposite the cylinder head hole (6) .

10A-338

Turn the crankshaft clockwise (timing end) smoothly until the crankshaft comes into contact with the TDC setting pin.

ENGINE AND LOWER ENGINE ASSEMBLY Timing belt: Removal

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

107271

Engage the pin (Mot. 1430) (2) in the camshaft pulley and cylinder head holes. Remove: - the set of 5 timing pins for the camshaft and crankshaft pulleys (Mot. 1430) , - the TDC setting pin (Mot. 1489) .

107262

Undo the tensioning roller bolt (7) . Loosen the timing tensioning roller by turning the eccentric cam using a 6 mm Allen key. Remove: - the timing belt, - the timing tensioning roller.

107260

Remove the crankshaft accessories pulley, locking the flywheel with a screwdriver.

10A-339

ENGINE AND LOWER ENGINE ASSEMBLY Timing belt: Removal

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790 II - ESSENTIAL EQUIPMENT

Special tooling required Mot. 1489

TDC locating pin.

- Protective gloves,

Mot. 1430

Set of 5 crankshaft and camshaft pulley timing pins.

- Large screwdriver, - Allen key ( 6 mm ), - Torx socket ( 14 ).

I - RECOMMENDATIONS FOR REPAIR III - REMOVAL IMPORTANT Wear protective gloves during every operation.

WARNING Never turn the engine in the opposite direction to its normal operating direction.

Do not run the engine without the accessories belt so as not to damage the crankshaft accessories pulley.

19654

Remove the upper timing cover by unclipping both

10A-340

tabs (1) .

ENGINE AND LOWER ENGINE ASSEMBLY Timing belt: Removal

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790

19654-1

Remove: - the high-pressure pump position sensor (2) , - the plastic bolt (3) . Unclip the three tabs (4) . Remove the lower timing cover.

10A-341

ENGINE AND LOWER ENGINE ASSEMBLY Timing belt: Removal

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790

19654-2

Remove the cylinder head suspended mounting.

19702 19650

Remove the TDC pin plug using a female torx socket ( 14 ).

10A-342

Turn the crankshaft to position the camshaft pulley hole (5) almost opposite the cylinder head hole (6) .

ENGINE AND LOWER ENGINE ASSEMBLY Timing belt: Removal

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790

19650-1

19655

Engage the pin (Mot. 1430) (2) in the camshaft pulley and cylinder head holes.

Screw in the TDC setting pin (Mot. 1489) (1) .

Remove: - the set of 5 timing pins for the camshaft and crankshaft pulleys (Mot. 1430) , - the TDC setting pin (Mot. 1489)

14489

Turn the crankshaft clockwise (timing end) smoothly until the crankshaft comes into contact with the TDC setting pin.

10A-343

ENGINE AND LOWER ENGINE ASSEMBLY Timing belt: Removal

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790

19656

Remove the crankshaft accessories pulley by locking the flywheel with a large screwdriver.

10A-344

ENGINE AND LOWER ENGINE ASSEMBLY Timing belt: Removal

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790

19656-1

Undo the tensioning roller bolt (7) . Loosen the timing tensioning roller by turning the eccentric cam using a 6 mm Allen key. Remove: - the timing belt taking care not to let the crankshaft timing sprocket fall out, - the timing tensioning roller.

10A-345

ENGINE AND LOWER ENGINE ASSEMBLY Timing belt: Removal

10A

K9K, and 732 or 764 III - REMOVAL

Special tooling required Mot. 1489

TDC locating pin.

Mot. 1430

Set of 5 crankshaft and camshaft pulley timing pins.

K9K, and 732

I - RECOMMENDATIONS FOR REPAIR

IMPORTANT Wear protective gloves during every operation.

WARNING Never turn the engine in the opposite direction to its normal operating direction.

Do not run the engine without the accessories belt so as not to damage the crankshaft accessories pulley.

112990

Remove the upper timing cover by unclipping both tabs (1) .

II - EQUIPMENT REQUIRED

- Protective gloves, - Large screwdriver, - Allen key ( 6 mm ), - Torx socket ( 14 ).

10A-346

ENGINE AND LOWER ENGINE ASSEMBLY Timing belt: Removal

10A

K9K, and 732 or 764

19654-1

Remove the plastic bolt (4) . Unclip the three tabs (3) . Remove the lower timing cover.

112989

Remove the cylinder head suspended mounting.

10A-347

ENGINE AND LOWER ENGINE ASSEMBLY Timing belt: Removal

10A

K9K, and 732 or 764

K9K, and 764

111742

Remove the cylinder head suspended mounting. 111740

Unclip the tab (8) . Turn the timing cover (9) in the direction of the arrow. Remove the plastic bolt (10) .

19650

Remove the TDC setting pin plug using a female torx socket ( 14 ).

111741

Unclip the three tabs (11) . Remove the timing cover.

10A-348

ENGINE AND LOWER ENGINE ASSEMBLY Timing belt: Removal

10A

K9K, and 732 or 764

107270

Turn the crankshaft to position the camshaft pulley hole (5) almost opposite the cylinder head hole (6) .

14489

Turn the crankshaft clockwise (timing end) smoothly until the crankshaft comes into contact with the TDC setting pin.

19650-1

Screw in the TDC setting pin (1) (Mot. 1489) . 109049

Engage the pin (Mot. 1430) (2) in the camshaft pulley and cylinder head holes. Remove: - the set of 5 pins for the camshaft and craknshaft pulleys (Mot. 1430) , - the TDC setting pin (Mot. 1489) .

10A-349

ENGINE AND LOWER ENGINE ASSEMBLY Timing belt: Removal K9K, and 732 or 764

107260

Remove the crankshaft accessories pulley, locking the flywheel with a screwdriver.

109046

Undo the tensioning roller bolt (7) . Loosen the timing tensioning roller by turning the eccentric cam using a 6 mm Allen key Remove: - the timing belt, - the timing tensioning roller.

10A-350

10A

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting There are three distinct tension procedures that must be observed, according to the engine family. Some engines require: - a pretensioning torque to be applied (using the special tooling for the engine type) to the belt section to be measured to compensate for all the belt play. - a pre-stress T1 slightly greater than the final fitting tension T2 to be applied. The purpose of these two operations is to stabilise the belt's internal voltage, to make a reliable tension measurement.

WARNING Replace any removed belt.

WARNING When replacing the timing belt specified by the manufacturer, the belt, tension wheel and pulley(s) must be replaced.

10A-351

10A

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768 II - PARTS AND CONSUMABLES FOR THE REPAIR

Special tooling required

Pièces à remplacer systématiquement Mot. 1430

Set of 5 crankshaft and camshaft pulley timing pins.

Mot. 1489

- Timing belt, - Timing belt tensioning roller, - Crankshaft accessories pulley bolt.

TDC locating pin.

Ingrédients - Silicone adhesive sealant, part no. 77 11 227 484 Tightening torquesm tensioning roller bolt

27 ± 2.7 Nm

the camshaft pulley wheel bolts

14 ± 1.4 Nm

the tensioning roller bolt

27 ± 2.7 Nm

the camshaft pulley wheel bolts

± 1.4 Nm 14±

the crankshaft accessories pulley M14 bolt

120 ± 12 Nm + 95˚ ± 15˚

III - ESSENTIAL EQUIPMENT

- Protective gloves, - Allen key ( 6 mm ), - Female torx socket ( 14 ), - Offset wrench ( 18 mm ), - Torque/angle wrench,

20 ± 2 Nm

TDC pin plug cylinder head suspended mounting bolts

21 ± 2.1 Nm

high-pressure pump position sensor bolt

8 Nm

I - RECOMMENDATIONS FOR REPAIR

IMPORTANT Wear protective gloves during every operation.

WARNING The belt must be replaced with a new one if it has been removed. Never turn the engine in the opposite direction to its normal operating direction. Do not run the engine without the accessories belt so as not to damage the crankshaft accessories pulley. When replacing the belt, always replace the tensioning rollers and fixed rollers.

10A-352

- Torque wrench - Cylinder head bolt tightening gauge (angular measuring type).

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768 IV - REFITTING

107263

Refit the timing tensioning roller. Place the tensioning roller spigot (1) in the cylinder head groove (2) . Engage the pin (1) (Mot. 1430) in the holes of the camshaft pulley and cylinder head, turning the camshaft using an 18 mm offset wrench if necessary. Check that the mark on the high-pressure pump (3) is opposite the bolt head (4) .

14489

Position the crankshaft so that it presses against the TDC setting pin (Mot. 1489) (the crankshaft sprocket cotter (5) must face upwards).

10A-353

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

107264

Remove one bolt from the camshaft pulley wheel. Loosen the two other camshaft pulley wheel bolts (6) by one turn.

10A-354

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

107265

Fit the timing belt, starting with the crankshaft sprocket, by aligning the marks on the belt with those on the crankshaft sprockets, the camshaft and the highpressure pump. Note: There should be 19 tooth belt grooves between the camshaft sprocket marks and the high-pressure pump, and 51 tooth belt grooves between the crankshaft sprockets and the high-pressure pump.

10A-355

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

19658

Position the tensioning roller adjustable index (7) opposite the spigot, turning the eccentric cam anticlockwise using a 6 mm Allen key. Tighten to torque the tensioning roller bolt ( 27 ± 2.7 Nm ) .

107268

Check that the camshaft pulley hub bolts are not fully up against the camshaft pulley wheel.

10A-356

10A

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

107266

Refit the bolt to the camshaft pulley wheel. Tighten to torque the camshaft pulley wheel bolts ( 14 ± 1.4 Nm ) . Remove: - the TDC setting pin (Mot. 1489) , - the set of 5 timing pins for the camshaft and crankshaft pulleys (Mot. 1430) .

107272

Tighten the old crankshaft accessories pulley bolt fitted with a spacer (which does not cover the timing sprocket mark) (8) onto the crankshaft.

10A-357

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

107270

Rotate the crankshaft clockwise through two revolutions (timing end), before the camshaft pulley hole (9) is opposite the cylinder head hole (10) . Screw the TDC setting pin (Mot. 1489) into the cylinder block. Bring the crankshaft slowly and smoothly against the TDC setting pin.

107271

Set the camshaft pulley using the (Mot. 1430) .

10A-358

107269

If the pin (Mot. 1430) does not engage: loosen the camshaft pulley wheel bolts by one turn at most, Turn the camshaft pulley hub using an 18 mm offset wrench to set the camshaft pulley hub timing. Do not retighten the camshaft pulley wheel bolts.

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

107267

Check: - that the high-pressure pump sprocket mark (14) is opposite the bolt head (13) , - that the crankshaft timing sprocket cotter (16) is positioned vertically at the top, - that there are 19 tooth belt grooves between the camshaft sprocket marks (11) and the high-pressure pump sprocket (12) , - that there are 51 tooth belt grooves between the crankshaft sprocket marks (15) and the high-pressure pump sprocket (12) .

Note: After two turns, the tensioning roller index markers may be in two different positions. The rotation of the tensioning roller eccentric depends on the position.

10A-359

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768 Second position

First position

111083

111082

111081

111081

Loosen the tensioning roller bolt by no more than one turn, holding it with a 6 mm Allen key.

Loosen the tensioning roller bolt by no more than one turn, holding it with a 6 mm Allen key.

Gradually align the adjustable index (21) in the middle of the timing window (22) , turning the key anticlockwise.

Gradually align the adjustable index (23) in the middle of the timing window (24) , turning the key clockwise. Tighten to torque: - the tensioning roller bolt ( 27 ± 2.7 Nm ) , ± 1.4 Nm ) . - the camshaft pulley wheel bolts ( 14± Remove the following tools: - TDC setting pin (Mot. 1489) ,

10A-360

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768 - the set of 5 timing pins for the camshaft and crankshaft pulleys (Mot. 1430) . Rotate the crankshaft clockwise through two revolutions (timing end), before the camshaft pulley hole is opposite the cylinder head hole. Screw the TDC setting pin (Mot. 1489) into the cylinder block. Bring the crankshaft slowly and smoothly against the TDC setting pin.

107260

Refit the accessories crankshaft pulley with a new bolt. Tighten to torque and angle (crankshaft in contact with the TDC setting pin) the crankshaft accessories pulley M14 bolt ( 120 ± 12 Nm + 95˚ ± 15˚ ) . Remove the following tools: - TDC setting pin (Mot. 1489) , 107271

Set the camshaft pulley using the (Mot. 1430) . If this is not possible, repeat the timing belt refitting operation.

10A-361

- the set of 5 timing pins for the camshaft and crankshaft pulleys (Mot. 1430) . Refit the TDC pin plug, coating the thread with SILICONE ADHESIVE SEALANT . Tighten to torque the TDC pin plug ( 20 ± 2 Nm ) .

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

107261

Refit the cylinder head suspended mounting. Tighten to torque the cylinder head suspended mounting bolts ( 21 ± 2.1 Nm ) .

10A-362

10A

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

19654-1

19659

Refit: - the lower timing cover, positioning the tab (19) in the inner timing cover hole (20) , - the timing cover plastic mounting bolt.

10A-363

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting

10A

K9K, and 274 or 276 or 714 or 716 or 718 or 766 or 768

19654

Refit the high-pressure pump position sensor. Tighten to torque the high-pressure pump position sensor bolt ( 8 Nm ) . Refit the upper timing cover.

10A-364

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790 II - PARTS AND CONSUMABLES FOR THE REPAIR

Special tooling required

Pièces à remplacer systématiquement Mot. 1430

Set of 5 crankshaft and camshaft pulley timing pins.

Mot. 1489

- Timing belt, - Timing belt tensioning roller, - Crankshaft accessories pulley bolt.

TDC locating pin.

Ingrédients - Silicone adhesive sealant, part no. 77 11 227 484 , Tightening torquesm

- Degreaser, part no. 77 11 224 559 .

timing pulley bolt

27 Nm

the crankshaft accessories pulley M12 bolt

60 Nm + 100˚ ± 10˚

the crankshaft accessories pulley M14 bolt

120 Nm + 95˚ ± 15˚

tensioning roller bolt to

27 Nm

TDC cap

20 Nm

cylinder head suspended mounting bolt

21 Nm

high-pressure pump position sensor bolt

8 Nm

III - EQUIPMENT REQUIRED

- Protective gloves, - Allen key ( 6 mm ), - Female torx socket ( 14 ), - Offset wrench ( 18 mm ), - Torque/angle wrench,

I - RECOMMENDATIONS FOR REPAIR

IMPORTANT Wear protective gloves during every operation.

WARNING The belt must be replaced with a new one if it has been removed. Never turn the engine in the opposite direction to its normal operating direction. Do not run the engine without the accessories belt so as not to damage the crankshaft accessories pulley. When replacing the belt, always replace the tensioning rollers and fixed rollers. It is essential to remove the grease from the end of the crankshaft, the camshaft timing sprocket and the bearing face of the crankshaft accessories pulley. This is to avoid timing slippage.

10A-365

- Torque wrench - Cylinder head bolt tightening gauge (angular measuring type).

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790 IV - REFITTING

19656-2

Refit: - the crankshaft timing sprocket, - the timing tensioning roller. Put the tensioning roller spigot (2) in the cylinder head groove (3) . Engage the pin (Mot. 1430) in the camshaft pulley and cylinder head holes at (4) . Turn the camshaft using an 18 mm offset wrench if necessary. Check that the mark on the high-pressure pump pulley (6) is opposite the bolt head (5) .

14489

Position the crankshaft so that it presses against the TDC setting pin (Mot. 1489) (the crankshaft groove (7) must face upwards).

10A-366

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790

19657

19658

Fit the timing belt, starting with the crankshaft sprocket, aligning the marks on the belt with those on the camshaft and high-pressure pump pulleys.

Position the tensioning roller adjustable index (8) opposite the spigot, turning the eccentric cam anticlockwise using a 6 mm Allen key. Tighten to torque the timing pulley bolt ( 27 Nm ) .

Note: There must be 19 tooth belt grooves between the marks of the high-pressure pump and camshaft pulleys.

Refit the accessories crankshaft pulley with a new bolt. Torque and angle-tighten (crankshaft in contact with the TDC setting pin): - the crankshaft accessories pulley M12 bolt ( 60 Nm + 100˚ ± 10˚ ) , - the crankshaft accessories pulley M14 bolt ( 120 Nm + 95˚ ± 15˚ ) Remove the following tools: - the set of 5 timing pins for the camshaft and crankshaft pulleys (Mot. 1430) , - the TDC setting pin (Mot. 1489) .

10A-367

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790

19702

Rotate the crankshaft clockwise through two revolutions (timing end), before the camshaft pulley hole (9) is opposite the cylinder head hole (10) . Screw the TDC setting pin (Mot. 1489) into the cylinder block. Bring the crankshaft slowly and smoothly against the TDC setting pin.

19655

Set the camshaft pulley using the (Mot. 1430) .

Note: There must be 19 tooth belt grooves between the camshaft pulley marks (11) and the highpressure pump pulley (12) Remove: - the TDC setting pin (Mot. 1489) , - the set of 5 timing pins for the camshaft and crankshaft pulleys (Mot. 1430) .

Note: After two turns, the tensioning roller index markers may be in two different positions. The rotation of the tensioning roller eccentric cam depends on the position.

10A-368

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790 First position

111083

111081

Loosen the tensioning roller bolt by no more than one turn, holding it with a 6 mm Allen key. Gradually align the adjustable index (17) in the middle of the timing window (18) , turning the key anticlockwise.

10A-369

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790 der block.

Second position

Bring the crankshaft slowly and smoothly against the TDC setting pin.

111082

19657

Set the camshaft pulley using the (Mot. 1430) . If this is not possible, repeat the timing belt refitting operation. Remove the following tools: - TDC setting pin (Mot. 1489) , - the set of 5 timing pins for the camshaft and crankshaft pulleys (Mot. 1430) Place a drop of SILICONE ADHESIVE SEALANT on the threading of the TDC pin plug. Tighten to torque the TDC cap ( 20 Nm ) .

111081

Loosen the tensioning roller bolt by no more than one turn, holding it with a 6 mm Allen key. Gradually align the adjustable index (19) in the middle of the timing window (20) , turning the key clockwise. Tighten to torque the tensioning roller bolt to ( 27 Nm ) . Rotate the crankshaft clockwise through two revolutions (timing end), before the camshaft pulley hole is opposite the cylinder head hole. Screw the TDC setting pin (Mot. 1489) into the cylin-

10A-370

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790

19654-2

Refit the cylinder head suspended mounting. Tighten to torque the cylinder head suspended mounting bolt ( 21 Nm ) .

10A-371

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790

19654-1

19659

Refit the timing cover, positioning the tab (15) in the inner timing cover hole (16) .

10A-372

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting

10A

K9K, and 260 or 270 or 272 or 700 or 702 or 704 or 706 or 710 or 712 or 722 or 724 or 728 or 729 or 750 or 752 or 760 or 762 or 790

19654

Refit the high-pressure pump position sensor. Tighten to torque the high-pressure pump position sensor bolt ( 8 Nm ) . Refit the upper timing cover.

10A-373

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting

10A

K9K, and 732 or 764 II - PARTS AND CONSUMABLES FOR THE REPAIR

Special tooling required

Parts always to be replaced Mot. 1430

Set of 5 crankshaft and camshaft pulley timing pins.

Mot. 1489

- Timing belt, - Timing belt tensioning roller, - Crankshaft accessories pulley bolt.

TDC locating pin.

Consumables - Silicone adhesive sealant, part no. 77 11 227 484 Tightening torquesm tensioning roller bolt

27 ± 2.7 Nm

the camshaft pulley wheel bolts

14 ± 1.4 Nm

the tensioning roller bolt

27 ± 2.7 Nm

the camshaft pulley wheel bolts

± 1.4 Nm 14±

the crankshaft accessories pulley M14 bolt

120 ± 12 Nm + 95˚ ± 15˚

III - ESSENTIAL EQUIPMENT

- Protective gloves, - Allen key ( 6 mm ), - Female torx socket ( 14 ), - Offset wrench ( 18 mm ), - Torque/angle wrench,

20 ± 2 Nm

TDC pin plug cylinder head suspended mounting bolts

21 ± 2.1 Nm

cylinder head suspended mounting bolts

21 ± 2.1 Nm

I - RECOMMENDATIONS FOR REPAIR

IMPORTANT Wear protective gloves during every operation.

WARNING The belt must be replaced with a new one if it has been removed. Never turn the engine in the opposite direction to its normal operating direction. Do not run the engine without the accessories belt so as not to damage the crankshaft accessories pulley. When replacing the belt, always replace the tensioning rollers and fixed rollers.

10A-374

- Torque wrench - Cylinder head bolt tightening gauge (angular measuring type).

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting

10A

K9K, and 732 or 764 IV - REFITTING

14489 109042

Position the crankshaft so that it presses on the TDC setting pin (Mot. 1489) (the crankshaft timing sprocket cotter (5) must face upwards).

109043

Refit the timing tensioning roller.

109042

Put the tensioning roller spigot (1) in the cylinder head groove (2) . Engage the pin (1) (Mot. 1430) in the holes of the camshaft pulley and cylinder head, turning the camshaft using an 18 mm offset wrench if necessary. Check that the high-pressure pump mark (3) has shifted one tooth to the right of the vertical axle (4) .

10A-375

Remove one bolt from the camshaft pulley wheel. Loosen the two other camshaft pulley wheel bolts (6) by one turn.

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting

10A

K9K, and 732 or 764

109044

Fit the timing belt, starting with the crankshaft sprocket, by aligning the marks on the belt with those on the crankshaft sprockets, the camshaft and the highpressure pump. Note: There should be 19 tooth belt grooves between the camshaft sprocket marks and the high-pressure pump, and 51 tooth belt grooves between the crankshaft sprockets and the high-pressure pump.

10A-376

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting K9K, and 732 or 764

19658

Position the tensioning roller adjustable index (7) opposite the spigot, turning the eccentric cam anticlockwise using a 6 mm Allen key. Tighten to torque the tensioning roller bolt ( 27 ± 2.7 Nm ) .

109047

Check that the camshaft pulley hub bolts are not fully up against the camshaft pulley wheel.

10A-377

10A

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting

10A

K9K, and 732 or 764

109045

Refit the bolt to the camshaft pulley wheel. Tighten to torque the camshaft pulley wheel bolts ( 14 ± 1.4 Nm ) . Remove: - the TDC setting pin (Mot. 1489) , - the set of 5 timing pins for the camshaft and crankshaft pulleys (Mot. 1430) .

107272

Tighten the old crankshaft accessories pulley bolt fitted with a spacer (which does not cover the timing sprocket mark) (8) onto the crankshaft.

10A-378

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting

10A

K9K, and 732 or 764

107270

Rotate the crankshaft clockwise through two revolutions (timing end), before the camshaft pulley hole (9) is opposite the cylinder head hole (10) . Screw the TDC setting pin (Mot. 1489) into the cylinder block. Bring the crankshaft slowly and smoothly against the TDC setting pin.

109049

Set the camshaft pulley using the (Mot. 1430) .

10A-379

109048

If the pin (Mot. 1430) does not engage: loosen the camshaft pulley wheel bolts by one turn at most, Turn the camshaft pulley hub using an 18 mm offset wrench to set the camshaft pulley hub timing. Do not retighten the camshaft pulley wheel bolts.

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting

10A

K9K, and 732 or 764

109045

Check that the crankshaft timing sprocket cotter (16) is positioned vertically at the top

Note: After two turns, the tensioning roller index markers may be in two different positions. The rotation of the tensioning roller eccentric cam depends on the position.

10A-380

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting

10A

K9K, and 732 or 764 Second position

First position

111083

111082

111081

111081

Loosen the tensioning roller bolt by no more than one turn, holding it with a 6 mm Allen key.

Loosen the tensioning roller bolt by no more than one turn, holding it with a 6 mm Allen key.

Gradually align the adjustable index (21) in the middle of the timing window (22) , turning the key anticlockwise.

Gradually align the adjustable index (23) in the middle of the timing window (24) , turning the key clockwise. Tighten to torque: - the tensioning roller bolt ( 27 ± 2.7 Nm ) , ± 1.4 Nm ) . - the camshaft pulley wheel bolts ( 14± Remove the following tools: - TDC setting pin (Mot. 1489) ,

10A-381

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting

10A

K9K, and 732 or 764 - the set of 5 timing pins for the camshaft and crankshaft pulleys (Mot. 1430) . Rotate the crankshaft clockwise through two revolutions (timing end), before the camshaft pulley hole is opposite the cylinder head hole. Screw the TDC setting pin (Mot. 1489) into the cylinder block. Bring the crankshaft slowly and smoothly against the TDC setting pin.

107260

Refit the accessories crankshaft pulley with a new bolt. Tighten to torque and angle (crankshaft in contact with the TDC setting pin) the crankshaft accessories pulley M14 bolt ( 120 ± 12 Nm + 95˚ ± 15˚ ) . Remove the following tools: - TDC setting pin (Mot. 1489) , 109049

Set the camshaft pulley using the (Mot. 1430) . If this is not possible, repeat the timing belt refitting operation.

10A-382

- the set of 5 timing pins for the camshaft and crankshaft pulleys (Mot. 1430) . Refit the TDC pin plug, coating the thread with SILICONE ADHESIVE SEALANT . Tighten to torque the TDC pin plug ( 20 ± 2 Nm ) .

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting K9K, and 732 or 764

K9K, and 732

112989

Refit the cylinder head suspended mounting. Tighten to torque the cylinder head suspended mounting bolts ( 21 ± 2.1 Nm ) .

10A-383

10A

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting

10A

K9K, and 732 or 764

19654-1

19659

112990

Refit the upper timing cover.

Refit: - the lower timing cover, positioning the tab (19) in the inner timing cover hole (20) , - the timing cover plastic bolt (25) .

10A-384

ENGINE AND LOWER ENGINE ASSEMBLY Timing belts: Refitting

10A

K9K, and 732 or 764

K9K, and 764

111741

111742

Refit the cylinder head suspended mounting. Tighten to torque the cylinder head suspended mounting bolts ( 21 ± 2.1 Nm ) .

19659

Refit: - the timing cover, positioning the tab (27) in the inner timing cover hole (28) , - the timing cover plastic bolt (26) .

10A-385